Mounting system for an electrical power delivery system

ABSTRACT

A mounting system includes a chassis, guide rods, and lifting elements. The guide rods extend from a back wall of the chassis and are suspended above a support platform of the chassis. A first guide rod is spaced a designated height above the support platform to be received within a channel of a module while the module is disposed on the support platform. The first guide rod guides movement of the module towards the back wall. As the module approaches the back wall, a first lifting element engages the module at an angled contact interface to lift the module off the support platform responsive to additional movement of the module towards the back wall. When the module is fully loaded, the module is supported by the back wall, the first lifting element, and/or the first guide rod, and is spaced apart from the support platform by a gap.

BACKGROUND Technical Field

Embodiments of the inventive subject matter described herein relate tosystems for delivering electrical power to various components forperforming work.

Discussion of Art

Some vehicles employ electrically motorized wheels for propulsion anddynamic braking. For example, hybrid vehicles may include engines inconjunction with alternators, rectifiers, inverters, and the like, thatare connected to the wheels of the vehicles via traction motors. Thealternator converts mechanical energy into electrical energy that istransmitted to the traction motors which transform the electrical energyback into mechanical energy to drive the wheels during a propel mode ofoperation.

At least some known power delivery systems that include alternators,rectifiers, inverters, motors, capacitors, resistors, inductors, and/orthe like have these components arranged in multiple discrete assembliesthat are spaced apart and electrically connected via conductiveelements, such as electrical cables. For example, the inverters may belocated proximate to the traction motors, and the rectifier may bespaced apart from the inverters and connected to the inverters vialengths of electrical cable of one or more meters. The discretepackaging and spacing between the components of the power deliverysystems may occupy significant space on a vehicle, which may be inlimited supply. Furthermore, the transmission of electric current overdistances between the various components may result in power loss (e.g.,due to resistance along the lengths of the conductors), which reducesefficiency. In addition, the distances between components may requireutilization of larger and heavier components (e.g., larger capacitors orthe like) than if the components were more closely packaged, whichincreases the vehicle weight and reduces fuel efficiency of the vehicle,as well as further limits available space on the vehicle. It may bedesirable to have systems and methods that differ from those that arecurrently available.

BRIEF DESCRIPTION

In one or more embodiments, a mounting system for mounting a module isprovided. The mounting system includes a chassis, multiple guide rods,and multiple lifting elements. The chassis includes a back wall and asupport platform. The guide rods are connected to and extend from theback wall. The guide rods are suspended above the support platform. Afirst guide rod of the guide rods is spaced a designated height abovethe support platform to enable the first guide rod to be received withina channel of the module while the module is disposed on the supportplatform. The first guide rod is configured to guide movement of themodule relative to the support platform in a loading direction towardsthe back wall. The lifting elements are disposed at or proximate to theback wall. As the module approaches the back wall, a first liftingelement of the lifting elements is configured to engage the module at anangled contact interface between the first lifting element and themodule to lift the module off the support platform responsive toadditional movement of the module in the loading direction. When themodule is in a fully loaded position relative to the chassis, the moduleis supported by the back wall, the first lifting element, and/or thefirst guide rod, and the module is spaced apart from the supportplatform by a gap.

In one or more embodiments, a mounting system is provided that includesa chassis and a first module. The chassis includes a back wall, multipleguide rods connected to and extending from the back wall, multiplelifting elements disposed at or proximate to the back wall, and asupport platform disposed below the guide rods. The first module isconfigured to be mounted to the chassis in a stack with other modules.The first module has a top side and a bottom side opposite the top side.The first module defines a channel configured to receive a first guiderod of the guide rods therein. The channel is spaced a designated heightabove the bottom side to enable the first guide rod to enter the channelwhile the bottom side is disposed on the support platform. The firstguide rod is configured to guide movement of the first module relativeto the support platform in a loading direction towards the back wall. Asthe first module approaches the back wall, a first lifting element ofthe lifting elements is configured to engage the first module at anangled contact interface between the first lifting element and the firstmodule to lift the first module off the support platform responsive toadditional movement of the first module in the loading direction. In afully loaded position relative to the chassis, the first module issupported by the back wall, the first lifting element, and/or the firstguide rod, and the bottom side of the first module is spaced apart fromthe support platform by a gap.

In one or more embodiments, a mounting system is provided that includesa module configured to be mounted to a chassis. The module includes ahousing having a top side, a bottom side opposite the top side, and arear side extending between the top side and the bottom side. The moduledefines a channel configured to receive a guide rod of the chassistherein. The channel is spaced a designated height above the bottom sideto enable the guide rod to enter the channel while the bottom side isdisposed on a support platform. Movement of the module in a loadingdirection towards a back wall of the chassis while the bottom sideengages the support platform is guided by the guide rod within thechannel. The module includes a ramp surface extending from the rear sideat a transverse orientation relative to the rear side. The ramp surfaceis configured to engage a lifting element of the chassis as the moduleapproaches the back wall to define an angled contact interface thatlifts the module off the support platform responsive to additionalmovement of the module in the loading direction relative to the liftingelement. The bottom side of the module is configured to be spaced apartfrom the support platform by a gap when the module is in a fully loadedposition relative to the chassis.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference is now made briefly to the accompanying drawings, in which:

FIG. 1 is a schematic circuit diagram of a system according to anembodiment;

FIG. 2 is a perspective view of an electrical power delivery systemaccording to an embodiment;

FIG. 3 is a first front perspective view of a module of an electricalpower delivery system according to an embodiment;

FIG. 4 is a second front perspective view of the module shown in FIG. 3;

FIG. 5 is a rear perspective view of the module shown in FIGS. 3 and 4;

FIG. 6 is a front perspective view of the module shown in FIGS. 3through 5 in a first partially assembled state according to anembodiment;

FIG. 7 is a front perspective view of the module shown in FIGS. 3through 6 in a second partially assembly state according to anembodiment;

FIG. 8 is a diagram illustrating a component stack-up within the housingof the module shown in FIGS. 3 through 7 according to an embodiment;

FIG. 9 is a front perspective view of a module of an electrical powerdelivery system according to an embodiment;

FIG. 10 is a front perspective view of the electrical power deliverysystem shown in FIG. 2 showing a connector side of a module stackaccording to an embodiment;

FIG. 11 is a front perspective view of the electrical power deliverysystem according to an embodiment;

FIG. 12 is a front perspective view of the electrical power deliverysystem shown in FIG. 11 with the module stack omitted according to anembodiment;

FIG. 13 is a perspective view of a mounting system for mounting modulesin a module stack according to an embodiment;

FIG. 14 is a side cross-sectional view of the mounting system showing afirst module of a module stack poised for mounting according to anembodiment;

FIG. 15 is a side cross-sectional view of the mounting system showingthe first module at a first intermediate loading position relative to achassis according to an embodiment;

FIG. 16 is an enlarged cross-sectional view of a portion of the mountingsystem shown in FIG. 15;

FIG. 17 is an enlarged cross-sectional view of the portion of themounting system shown in FIGS. 15 and 16 showing the module during asecondary loading stage in which the module moves both laterally andvertically relative to the chassis;

FIG. 18 is a cross-sectional view of the mounting system shown in FIGS.15 through 17 showing the module in a fully loaded position relative tothe chassis according to an embodiment;

FIG. 19 is a side cross-sectional view of the mounting system showingthe first module in the fully loaded position and a second module poisedfor mounting according to an embodiment;

FIG. 20 is a cross-sectional view of the mounting system showing boththe first and second modules in the fully loaded position relative tothe chassis according to an embodiment;

FIG. 21 is a side view of the mounting system showing four modulesmounted to the chassis in a module stack according to an embodiment;

FIG. 22 is a cross-sectional view of the mounting system according to afirst alternative embodiment showing a first intermediate loading stageof the first module;

FIG. 23 is a cross-sectional view of the mounting system according tothe alternative embodiment shown in FIG. 22 showing a secondintermediate loading stage of the first module;

FIG. 24 is a cross-sectional view of the mounting system according tothe alternative embodiment shown in FIGS. 22 and 23 showing the firstmodule at the fully loaded position;

FIG. 25 is a cross-sectional view of the mounting system according to asecond alternative embodiment showing an intermediate loading stage ofthe first module;

FIG. 26 is a cross-sectional view of the mounting system according tothe alternative embodiment shown in FIG. 25 showing the first module atthe fully loaded position;

FIG. 27 is a perspective view of a portion of the electrical powerdelivery system shown in FIG. 2;

FIG. 28 is a side view of the electrical power delivery system showingtwo support structures according to the embodiment shown in FIG. 27;

FIG. 29 is a perspective view of a portion of a first shell member ofone of the support structures shown in FIGS. 27 and 28 according to anembodiment;

FIG. 30 is a perspective view of a portion of the second shell member ofthe support structure;

FIG. 31 illustrates a portion of one of the support structures shown inFIGS. 27 through 30 in a partially assembled state according to anembodiment;

FIG. 32 shows the portion of the support structure of FIG. 31 in a fullyassembled state according to an embodiment;

FIG. 33 illustrates a support structure for mechanically supportingmultiple electrical energy storage devices of the electrical powerdelivery system according to a first alternative embodiment;

FIG. 34 illustrates a support structure for mechanically supportingmultiple electrical energy storage devices of the electrical powerdelivery system according to a second alternative embodiment; and

FIG. 35 illustrates a support structure for mechanically supportingmultiple electrical energy storage devices of the electrical powerdelivery system according to a third alternative embodiment.

DETAILED DESCRIPTION

Embodiments of the inventive subject matter described herein relate tosystems for delivering electrical power to various components forperforming work. Certain embodiments relate to systems for deliveringelectrical power to motors on vehicles. In one embodiment, a mountingsystem is provided for mounting one or more modules on an electricalpower delivery system. The system may include a chassis, guide rods, andlifting elements. The guide rods may extend from a back wall of thechassis and may be suspended above a support platform of the chassis. Afirst guide rod of the guide rods may be spaced a designated heightabove the support platform to be received within a channel of a modulewhile the module is disposed on the support platform. The first guiderod may guide movement of the module towards the back wall. As themodule approaches the back wall, a first lifting element of the liftingelements may engage the module at an angled contact interface to liftthe module off the support platform responsive to additional movement ofthe module towards the back wall. When the module is fully loaded, themodule may be supported by the back wall, the first lifting element,and/or the first guide rod. The module may be spaced apart from thesupport platform by a gap.

A schematic circuit diagram of a system 100 according to an embodimentis shown in FIG. 1. The system may be a power delivery system useful forpropulsion. The system may be onboard a vehicle. The system may includea traction bus 102. The traction bus may have a positive rail 104 and anegative rail 106. The system may include an engine 108 and analternator 110. The alternator may be mechanically coupled to the enginevia a mechanical linkage 112. The mechanical linkage may be a shaft.

A suitable engine may be a diesel engine, a gasoline engine, amulti-fuel engine, or the like. The engine drives the alternator via themechanical linkage, such as by rotating the shaft to rotate a rotor ofthe alternator. The alternator and engine may be selected with referenceto their performance characteristics relative to each other (such as thetorque output of the engine with the torque acceptance level of thealternator, the engine speed vs the alternator speed, and the like), andwith further reference to the intended end use application. Depending onthe voltage, current demands of the application, various components andmaterials may be selected. Further, spacing and air gaps may determinespacing and insulation values for some components. Lastly, thermalconsiderations may be used to select suitable components for such enduse applications.

With regard to the alternator 110, the alternator receives mechanicaltorque and from that generates electrical energy (e.g., electriccurrent) that is conveyed along the traction bus 102 to variouscomponents to power various loads. The alternator is electricallyconnected to a rectifier 114. The alternator converts mechanical energyfrom the engine to electric current in alternating current (AC) format(referred to herein as AC current). The rectifier receives the ACcurrent from the alternator and converts the AC current to electriccurrent in direct current (DC) format (referred to herein as DCcurrent). The DC current output from the rectifier is supplied to thepositive rail of the traction bus. The traction bus, including thepositive and negative rails, may be referred to as a DC link thatprovides DC current to various components of the system.

The system may include two motor subassemblies 116 connected between thepositive and negative rails of the traction bus. Each motor subassemblymay include a respective inverter 118 and traction motor 120. Theinverters are labeled as INV1 and INV2 in FIG. 1, and the tractionmotors are labeled as TM1 and TM2. The two motor subassemblies may becoupled to wheels on the same axle or different axles of a vehicle. Thetraction motors may be AC motors. The inverters may convert DC currentfrom the rectifier to three-phase AC current for the respective tractionmotors. The system optionally may have more or less than two motorsubassemblies. In another embodiment, the motors may be DC motors, withinverters being configured to convert DC from the DC link into a DCpower waveform suitable for powering the DC motors.

The system also may include at least one chopper circuit 126 (referredto herein as a chopper) electrically connected to a resistance grid 122.The resistance grid may include resistive elements 128 configured todissipate electric current as heat. The chopper controls the flow ofelectric current to the resistance grid. In the illustrated embodimentthe chopper is connected in series with one or more of the resistiveelements to define a resistor leg 124 connected between the positive andnegative rails. Only one chopper and only one resistor leg is shown inFIG. 1, but the system may have multiple choppers and/or multipleresistor legs arranged in parallel orientation in another embodiment.The resistance grid optionally may include a physical housing structure.The resistance grid is configured to dissipate thermal energy (e.g.,heat) that is generated during dynamic braking. Optionally, theresistance grid may also include one or more blowers for enhancing thedissipation of heat from the grid box to an external environment. Thechopper may be used to regulate a desired voltage on the traction bus(e.g., DC link) by modulating an effective resistance along the resistorleg between the positive and negative rails. The chopper may regulateelectric current along the traction bus and prevent large power demandson the engine during a transition between a propel mode of operation anda dynamic braking mode of operation. Although the chopper is shown inFIG. 1 as separate from the resistance grid, the chopper optionally maybe incorporated into the resistance grid.

The chopper is an electronic switching device controlled to switchbetween open and closed states. In the open state, the chopper does notconduct electric current from the positive rail through the respectiveresistor leg. In the closed state, the chopper conducts electric currentthrough the resistor leg. When the chopper is in the closed state, atleast some of the electric current conducted along the resistor leg isconverted to heat that is dissipated from the grid box. The chopper mayinclude internal electrical components such as one or more transistors,diodes, inductors, and/or the like. The transistors may include orrepresent insulated gate bipolar junction transistors (IGBTs), or othertypes of transistors. The resistive elements may be resistors thatconvert electrical energy into thermal energy. Although shown in FIG. 1as separate from the chopper in some embodiments the resistive elementsmay be integral components of the chopper. The operation of the choppermay be controlled by signals received that are generated by one or moreprocessors.

The system is selectively switchable to different operating modes. Theseoperating modes may include the propel mode and the dynamic brakingmode. In the propel mode, electrical energy may be generated by thealternator (which is powered by the engine) and conveyed along thetraction bus to the traction motors for powering propulsion. Propulsionmay include propelling a vehicle on which the system is integrated. Forexample, the traction motors may be mechanically coupled to wheels of avehicle, and may rotate the wheels based on the electrical energyreceived. In the dynamic braking mode, the alternator may not be used topropel the vehicle. Rather, the vehicle operates in the dynamic bakingmode to slow the vehicle by using the vehicle momentum and the existingrotational torque of the wheels to generate electrical energy via thetraction motors (rather than the alternator). The electric currentgenerated by the traction motors may be supplied to the traction bus.Dynamic braking may be used alone or in combination with friction-basedbrakes to slow the vehicle. In one embodiment, at least some of theelectrical energy generated by the traction motors may be conveyed to aresistor grid to dissipate the energy as heat. Alternatively, if thereis an electrical energy storage system, at least some of the electricalenergy may be directed to a battery or another electrical storage devicefor storage and future use of the electrical energy. Alternatively, someof the electrical energy may be used in real time to power variouselectronic devices that consume electrical power (e.g., compressors,lights, pumps).

FIG. 2 is a perspective view of an electrical power delivery system 200according to an embodiment. The electrical power delivery system has anintegrated, modular design, and may represent a portion of the systemshown in FIG. 1. For example, the electrical power delivery system mayrepresent several components and/or circuitry of the system disposedbetween the alternator 110 and the traction motors 120, such asrectifier 114, traction bus 102 (e.g., DC link), chopper 126, andinverters 118. The electrical power delivery system may includealternate or additional components (that are of a similar or non-similartype or configuration) than the components in the system of FIG. 1,and/or may lack one or more of the components that are included in thesystem.

The electrical power delivery system supplies electric current forpowering one or more loads. The electrical power delivery system may beincorporated onto the vehicle, such as an OHV, a rail vehicle (e.g.,locomotive), a marine vessel, an automobile, or the like, for thepurpose of delivering electric current with designated properties tomotors used to propel the vehicle. The designated properties may includea format (i.e., electrical waveform) of the current (e.g., DC or AC), aphase of the current, a voltage of the current, a flow of the current,and/or the like. The electrical power delivery system may be configuredto convert, modify, and/or transform received electric current to supplycurrent with the designated properties to the loads. In one or moreembodiments, the electrical power delivery system receives electriccurrent from an alternator on a vehicle, and supplies electric currentto one or more traction motors used to rotate a wheel or a propeller ofthe vehicle.

In one embodiment, the electrical power delivery system may berelatively compact. A compact package is a technical effect in that itmay reduce the footprint and therefore occupy less space. In addition,the electrical power delivery system presented herein may be modular.Modularity may enable quick and efficient repair and replacement of thecomponents. The close proximity of the components, due to the modularityand compactness, may reduce resistance-based energy loss and may enablereduction of the size and/or weight or at least some of the components.

The electrical power delivery system 200 may include various componentsthat are coupled together to in a discrete package. The componentsinclude a module stack 202 of multiple modules 204, a conductive plane(meaning a planar body that is made of metal or otherwise able toconduct electricity, e.g., bus bar) 206, and one or more electricalenergy storage devices 208. The modules in the module stack (alsoreferred to herein as stack) are arranged side by side along a stackaxis 210. Each of the modules may include a housing 212 and internalelectrical components (shown in FIGS. 6 through 9) held by and/or withinthe housing. The stack may be arranged such that the stack axis isvertically oriented. For example, the stack axis may be parallel to thedirection of gravity (gravitational force) or substantially parallel tothe direction of gravity (e.g., within a designated margin of +/−1%, 2%,5%, 1°, 2°, 5°, or the like from the direction of gravity). For example,a first module 204A is the lowermost module in the stack, a secondmodule 204B is immediately above the first module 204A, a third module204C is immediately above the second module 204B, and a fourth module204D is the uppermost module in the stack. The second and third modules204B, 204C are inner modules in the stack because these modules arebordered by the first and fourth modules 204A, 204D, which representouter modules located at corresponding ends of the stack. In analternative embodiment, the modules may be stacked in a differentarrangement, such as in a stack axis that is orthogonal to a vertical(or height) axis. The stack optionally may include more or less thanfour modules to satisfy application specific parameters.

The modules have functionality relating to electric currentmodification, transmission, distribution, dissipation, and/or the like.For example, the internal electrical components of the modules mayinclude transistors, diodes, inductors, conductors, switches, controlcircuit boards, connectors, and/or the like, as described herein in moredetail. In an embodiment, at least two of the modules in the stack havedifferent functions from one another. For example, one of the modulesmay be used for dissipating electric current, and another module may beused for distributing and/or modifying electric current. Optionally, atleast two of the modules in the stack may be utilized to provide thesame functions as each other.

The housings of the modules may have the same form factor as oneanother. The form factor refers to the overall size and shape of thehousing, such as the general dimensions along three mutuallyperpendicular axes. Two housings with the same form factor may not beidentical to one another due to differences in materials, the number,location, size, and/or shape of openings through walls of the housings,the number, location, size, and/or shape of features on the walls of thehousings, and the like. In FIG. 2, all four of the modules in the stackhave the same form factor. For example, the housings have rectangularprism shapes (e.g., parallelepiped) that have greater lateral widths andlongitudinal depths than vertical heights (along the stack axis).

In an embodiment, at least two of the modules have different internalelectrical components than one another. For example, the internalelectrical components of the fourth module 204D may have a differentconfiguration than the internal electrical components of the thirdmodule 204C. The configuration of internal electrical components mayrefer to the type of electrical components and the arrangement of thecomponents in an assembly within the respective module. The respectiveconfiguration of internal electrical components affects thefunctionality of the module. In an embodiment, the internal electricalcomponents of at least two of the modules in the stack have the sameconfiguration as one another, such that the at least two modules havethe same type and arrangement of electrical components. For example, theinternal electrical components of the fourth module 204D may be the sameconfiguration as the internal electrical components of the second module204B. The modules that have the same internal component configurationsmay be replicas (or copies) of one another, such that they are composedof the same type of components and are produced using the samemanufacturing and assembly steps.

In an embodiment, at least one of the modules is an inverter module thathas a functionality similar to each of the inverters 118 of the system100 shown in FIG. 1. The inverter module may receive electric currentand modify the electric current to have designated electricalcharacteristics or properties for use by a particular load, such as atraction motor. For example, the inverter module may convert DC currentto AC current for use by the particular load.

In an embodiment, at least one of the modules in the stack is arectifier module that has a functionality similar to the rectifier 114shown in FIG. 1. The rectifier module may receive AC current from apower source, such as an alternator, and may convert the AC current toDC current. The rectifier module may also distribute the DC current tovarious other modules in the stack, such as to the one or more invertermodules.

The modules in the stack may also include at least one chopper modulethat functions similar to the chopper 126 shown in FIG. 1. Among otherfunctions, the chopper module may be configured to dissipate current asheat by conveying received current to a resistance grid that may includeone or more resistance elements. The chopper module may receive currentfrom the rectifier module.

In a non-limiting example embodiment, the stack may include two invertermodules, one rectifier module, and one chopper module. The rectifiermodule is configured to distribute electric current received from apower source to the two inverter modules. Positioning the rectifiermodule between the inverter modules allows a similar current pathdistance from the rectifier module to each of the inverter modules,which may enable more uniform current distribution than if the rectifiermodule is disposed at an end of the stack. The two inverter modules maysupply the current received from the rectifier module to correspondingloads, such as to two different traction motors. The chopper module maybe disposed at an end of the stack. The chopper may generate and emitwaveform pulses out from and/or towards the resistance grid along acurrent loop. Positioning the chopper module at the end of the stack mayreduce the influence of electromagnetic interference (EMI) on themodules in the stack due to the waveform pulses than if the choppermodule is more centrally located because of the greater separationdistance from the chopper to at least some of the other modules.

In a particular arrangement of the non-limiting example embodimentdescribed above, the first module 204A is a chopper module, the secondmodule 204B is a first inverter module, the third module 204C is arectifier module, and the fourth module 204D is a second invertermodule. Thus, the first inverter module 204B is disposed between therectifier module and the chopper module. Optionally, the second invertermodule may be placed at the top end of the stack for thermal damagesuppression and/or mitigation purposes. For example, because heat andfire generate propagates vertically upward, if the second invertermodule at the top of the stack ignites or experiences thermal runaway,there is a reduced likelihood of thermal damage spreading downward toother modules in the stack than if the same inverter module is locatedbelow other modules in the stack. Furthermore, the uppermost module maybe the most exposed module in the stack, providing the most access foractive cooling and fire suppression techniques, such as dumping fireretardant on the module. For this reason, the stack may be arranged suchthat the inverter module with the greatest likelihood of fire and/orthermal runaway is placed at the top of the stack, and the otherinverter module is placed below, between the rectifier module and thechopper module. In an alternative embodiment, the chopper module may belocated at the top of the stack and the rectifier module may be thesecond module 204B between the two inverter modules. The arrangement ofthe modules may be based on an orientation and/or location of theelectrical power delivery system onboard a vehicle, such as the locationrelative to a cooling fluid, relative to traction motors, relative to anelectrical energy power source (e.g., an alternator), and the like.

The conductive plane 206 of the electrical power delivery system 200 isreferred to herein as a bus bar. The bus bar is electrically connectedto one or more modules in the stack. For example, the bus bar may beelectrically connected between the rectifier module and the invertermodules to convey current from the rectifier module to the invertermodules. The bus bar may operate as a DC link, similar to the tractionbus 102 shown in FIG. 1. The bus bar may include multiple conductivelayers that are laminated together. The conductive layers may be metalsheets. The bus bar may be planar and oriented along a plane 214. In theillustrated embodiment, the plane of the bus bar is parallel to thestack axis 210 of the module stack. The bus bar is mounted along a side216 of the module stack and extends across multiple of the modules. Theside 216 of the stack is referred to herein as a bus side. The bus barhas a first side 218 and a second side 220 opposite the first side 218.The first side 218 faces towards the module stack. The second side 220faces away from the module stack. The bus bar may be mounted to themodule stack via one or more fasteners such as bolts, screws, nuts,clamps, clips, and/or the like. The bus bar may be individuallyelectrically connected to the modules via one or more conductors thatextend between the first side of the bus bar and the bus side of themodule stack. The conductors may include rigid metal contacts, flexiblecables, and/or the like.

The rectifier module may be centrally located within the stack as one ofthe inner modules to achieve a uniform and even current distributionfrom the rectifier module along the bus bar to the inverter modules(relative to locating the rectifier module at an end of the stack). Forexample, the rectifier module may supply DC current to the bus bar alonga central area thereof, and the bus bar spreads or distributes thecurrent in opposite directions (up and down) to the different invertermodules. Arranging the components such that the current spreads inopposite directions along the bus bar may reduce the local thermal loadon the bus bar and/or the modules. Reducing the local thermal load mayreduce the risk of heat-related damage due to fire, thermal runaway, andthe like, and may extend the operational lifetime and/or the increasethe performance capability of the power delivery system 200.

The electrical power delivery system in the illustrated embodiment mayinclude multiple electrical energy storage devices 208 mounted to thebus bar and electrically connected to the bus bar. The electrical energystorage devices commonly extend from the second side 220 of the bus bar(e.g., in a direction away from the module stack). The bus bar istherefore disposed between the energy storage devices and the modulestack. In an embodiment, the energy storage devices are capacitors, suchas DC link filter capacitors. The electrical energy storage devices arereferred to herein as capacitors, although another type of electricalenergy storage device, such as battery or fuel cells, may be used inaddition to capacitors or instead of capacitors based onapplication-specific requirements.

The capacitors are cylindrical and extend from the bus bar alongrespective central axes 222. In the illustrated embodiment, thecapacitors extend from the bus bar such that the central axes 222 areparallel to one another and perpendicular to the stack axis 210. Thecentral axes 222 may be perpendicular to the plane 214 of the bus bar.The electrical power delivery system may include an array of eightcapacitors in the illustrated embodiment, but may have more or lesscapacitors in other embodiments. The capacitors may have the sameconfiguration, or at least some of the capacitors may have differentconfigurations (e.g., different size, solid vs. electrolytic, polymervs. ceramic, etc.). In the illustrated embodiment, the capacitors aredisposed proximate to the module stack such that only the thickness ofthe bus bar between the first and second sides 218, 220 may separate thecapacitors from the module stack. The close proximity of the capacitorsto the module stack may enable reducing the number of capacitors and/orthe sizes of the capacitors relative to the number and/or size of thecapacitors that would be required to provide a similar degree ofperformance if the capacitors were spaced farther from the module stack.

The electrical power delivery system 200 shown in FIG. 2 has arelatively compact, modular shape that is useful in variousapplications, including vehicular applications. For example, therectifier module may be electrically connected to a power source on avehicle, such as an alternator that is powered by an engine. Optionally,a side 224 of the module stack that is opposite the bus side 216 mayhave electrical connectors for electrically connecting the modules toconductors, such as electrical cables and wires, that convey electriccurrent to and from devices remote from the power delivery system. Theside 224 is referred to herein as a connector side 224. In anembodiment, the rectifier module is electrically connected to one ormore electrical cables or other conductors that extend from theconnector side 224 of the module stack to the alternator (or other powersource) for conveying current to the rectifier module. The rectifiermodule may receive AC current from the alternator and converts the ACcurrent to DC current. The rectifier module supplies the DC current tothe bus bar, which distributes the DC current to both of the invertermodules. The inverter modules may convert the DC current received intoAC current and convey the AC current remotely. For example, each of theinverter modules may be electrically connected, via one or moreelectrical cables or other conductors, to a different correspondingtraction motor that is used for rotating one or more wheels and/or oneor more propellers of the vehicle. The cables may extend from theinverter modules along the connector side 224 of the module stack.

In a non-limiting example, the electrical power delivery system may beimplemented onboard an OHV, such as a large mining truck. The OHV may berated for a payload weighing up to or in excess of 100 tons. Theelectrical power delivery system is configured to supply current totraction motors for rotating large wheels of the OHV. For example, theOHV may have a nominal system power of 1200 horsepower. The system powermay be delivered to the traction motors through the electrical powerdelivery system.

FIG. 3 is a first front perspective view of a module 300 of anelectrical power delivery system according to an embodiment. FIG. 4 is asecond front perspective view of the module 300 shown in FIG. 3. FIG. 5is a rear perspective view of the module 300 shown in FIGS. 3 and 4. Themodule 300 may be one of the modules 204 of the electrical powerdelivery system 200 shown in FIG. 2. The module 300 may include ahousing 302 and internal electrical components 304 held by the housing302.

The housing of the module extends from a front end 306 to a rear end 308that is opposite the front end 306. The front end is visible in FIGS. 3and 4. The rear end is visible in FIG. 5. The housing may include afront side 310 at the front end and a rear side 312 at the rear end. Thehousing also has several walls extending from the front side 310 to therear side 312, including a top side 314, a bottom side 316, a bus side318, and a connector side 320. The bottom side is opposite the top side.The bus side is opposite the connector side. When assembled in themodule stack the bus side of the module may define a portion of the busside 216 (shown in FIG. 2) of the module stack, and the connector sideof the module may define a portion of the connector side 224 (FIG. 2) ofthe module stack. The view in FIG. 3 shows the front side, the top side,and the connector side of the housing. The view in FIG. 4 shows thefront side, the bottom side, and the bus side. The view in FIG. 5 showsthe rear side, the top side, and the bus side. In a non-limitingexample, the height of the housing between the top and bottom sides maybe between four and ten inches, such as approximately six inches (e.g.,within 0.5 inches thereof); the lateral width of the housing between thebus and connector sides may be between 18 and 24 inches, such asapproximately 21 inches; and the longitudinal depth of the housingbetween the front and rear sides (not including the shelf) may bebetween 16 and 21 inches, such as approximately 18 inches.

In an embodiment, the housing may include a frame 322, an upper panel324, and a lower panel 326. The frame may be a unitary, monolithic(e.g., one-piece) body that is seamless. Optionally, the frame may be amonolithic body composed of a composite material, such as a glass-filledpolyester. The upper panel is mounted to the frame 322 to define atleast a portion of the top side of the housing. The lower panel ismounted to the frame 322 to define at least a portion of the bottom sideof the housing. The upper and lower panels may be about planar, exceptoptionally along edges thereof for coupling to the frame. The housingmay include a shelf 328 that projects forward beyond the front side,such that a distal end of the shelf defines the front end of thehousing. The shelf may be coplanar with the upper panel. For example, atop of the shelf may define a section of the top side of the housing. Inthe illustrated embodiment, the shelf may include one or more handles330 for manually moving (e.g., sliding) the module relative to themodule stack, such as for loading the module into the stack or removingthe module from the stack. In an alternative embodiment, the frame maybe an assembly of multiple discrete frame members coupled together atjoints via fasteners, adhesives, or the like.

The housing defines a front plenum opening 332 through the front side310 and a rear plenum opening 334 through the rear side 312. The frontand rear plenum openings are fluidly connected to an interior cavity 336(shown in FIG. 6) of the housing to provide a passageway for coolingfluid (e.g., air) through the housing to absorb and dissipate heat fromthe module. The module in the illustrated embodiment may include aplenum gasket 338 mounted to the rear side and surrounding the rearplenum opening. The plenum gasket may be at least partially embedded inthe rear side, such as within a groove along the rear side. The plenumgasket is at least partially compressible to provide a seal between thehousing and a back wall of a chassis when the module is loaded in thestack. The housing also may include channels 340 that extendlongitudinally through the housing from the front end to the rear end.The channels are open along the front side and the rear side. Thechannels are configured to receive guide rods therein for aligning andguiding movement of the module relative to the module stack when loadingand unloading the module.

In an embodiment, one or more of the internal electrical components 304of the module may protrude out of the housing to be exposed along anexterior of the housing. For example, several conductive power tabs 342are exposed along the connector side of the housing. The power tabs 342are configured to be electrically connected to one or more electricalconnectors for conveying current to and/or from the module stack to aremote device, such as a power source or a load. The module also mayinclude several connectors 344 mounted to the housing along theconnector side proximate to the front side. The connectors 344 may beused, for example, to connect wires for transmitting control and/or datasignals to control components within the module for controllingoperation of the module.

FIG. 6 is a front perspective view of the module 300 shown in FIGS. 3through 5 in a first partially assembled state according to anembodiment. FIG. 7 is a front perspective view of the module 300 shownin FIGS. 3 through 6 in a second partially assembly state according toan embodiment. The upper panel is remote from the frame 322 of thehousing 302 to show internal electrical components 304 within theinterior cavity 336 of the housing. In FIG. 6, the module may include aheat sink 346 and internal electrical components mounted on the heatsink. The internal electrical components may include transistors 348,such as insulated gate bipolar junction transistors (IGBTs) or the like.The internal electrical components also may include gate drivers 350that are electrically connected between the transistors and ribboncables 352. The internal electrical components disposed above the heatsink 346, including the transistors and the gate drivers, may representpower electronics 354 that are used for handling (e.g., receiving andsupplying) and/or modifying (e.g., converting and transforming) electriccurrent used to power loads.

In FIG. 7, the internal electrical components also include conductivebus bars 356 that are installed onto the power electronics 354 shown inFIG. 6. The conductive bus bars are electrically connected to thetransistors. Each of the conductive bus bars may include one or moreconductive layers that are laminated. The bus bars electrically connectthe power electronics within the housing to the conductive power tabs342 along the exterior of the housing.

In a non-limiting example, the module 300 may represent one of theinverter modules in the module stack and/or a chopper module in themodule stack. For example, the inverter modules and the chopper modulemay have internal electrical components with the same configuration(e.g., the same types and arrangement of components), although theinverter modules are utilized to perform different functions than thechopper module. Therefore, the illustrated module optionally may beutilized as either one of the inverter modules or the chopper module.

FIG. 8 is a diagram illustrating a component stack-up within the housingof the module 300 shown in FIGS. 3 through 7 according to an embodiment.The conductive bus bars 356 (shown in FIG. 7) are disposed at the top ofthe stack immediately above the power electronics 354 (FIG. 6). Thepower electronics are disposed immediately above the heat sink 346 (FIG.6), which is referred to as a first heat sink. The first heat sink isdisposed immediately above a second heat sink 360, which is immediatelyabove control electronics 362. The control electronics may include oneor more circuit boards, integrated circuits, and/or the like thatinclude one or more processing devices for controlling operations of themodule. The control electronics may be mounted directly on the secondheat sink. One or both of the heat sinks may include fins fordissipating heat to cooling air that flows through the interior cavityof the housing between the plenum openings 332 and 334 shown in FIGS. 3through 5. The power electronics and the control electronics are spacedapart along opposite sides of the heat sinks (and the cooling air flowthrough the heat sinks). In an alternative embodiment, the module mayhave a single heat sink or at least three heat sinks depending on anamount of heat dissipation required for a particular application.

FIG. 9 is a front perspective view of a module 400 of an electricalpower delivery system according to an embodiment. The module may be oneof the modules 204 of the electrical power delivery system 200 shown inFIG. 2. The module 400 may include a housing 402 and internal electricalcomponents 404 held by the housing 402. An upper panel of the housing isomitted in FIG. 9 to show some of the internal electrical components 404within the housing 402 that would otherwise be concealed by the upperpanel. The housing 402 may be a replica of, or at least similar to, thehousing 302 of the module 300 shown in FIGS. 3 through 7. For example,the housing 402 may have the same form factor as the housing 302. Asdescribed above, all of the modules in the module stack may have thesame form factor, such as the same size (e.g., dimensions) and shape.

In a non-limiting example, the module 400 in FIG. 9 may represent therectifier module (e.g., 204C) of the module stack 202 in FIG. 2. Atleast some of the internal electrical components 404 of the rectifiermodule 400 differ from the internal electrical components 304 of theinverter and/or chopper module 300. For example, the module 400 has asingle conductive bus bar 406 as opposed to multiple discrete bus bars.The bus bar mechanically and electrically connects to three power tabs342 extending along an exterior of the housing 402 for connecting toelectrical cables. The electrical cables may connect the rectifiermodule 400 to the alternator or other power source. In addition to thedifference in the bus bar, the internal electrical components 404 of therectifier module 400 may have other differences from the internalelectrical components 304 of the inverter and/or chopper module 300. Forexample, the rectifier module 400 may have a snubber plate instead ofthe second heat sink 360 (shown in FIG. 8) and a snubber card instead ofa control circuit board or integrated circuit. The rectifier module 400may also have different diodes and/or other components than the module300. Optionally, the rectifier module 400 may include a heat sink thatis a replica of, or at least similar to, the heat sink 346 of the module300 shown in FIGS. 6 and 8.

FIG. 10 is a front perspective view of the electrical power deliverysystem 200 showing the connector side 224 of the module stack 202according to an embodiment. The conductive power tabs 342 of the modules204 are connected to corresponding electrical cables 502 that extendremote from the module stack. For example, the cables connected to thepower tabs of the inverter modules 204B, 204D may extend to differentcorresponding traction motors, or other loads. The cables connected tothe rectifier module 204C may extend to an alternator, or another powersource. The cables connected to the chopper module 204A may extend to aresistance grid for dissipating electrical energy as heat.

The electrical power delivery system may include a chassis 504 on whichthe modules are mounted. The chassis structurally supports the modules.The chassis may include a back wall 506 and one or more supportplatforms 508. The chassis has two support platforms in the illustratedembodiment. The support platforms are disposed under the module stack.The back wall may be a bulkhead that divides and separates two spaces.The rear sides of the modules, or at least the plenum gaskets 338thereon (shown in FIG. 5), may engage and abut against the back wallwhen the modules are loaded into the module stack. Optionally, the busbar 206 mounted along the module stack may be independently mounted tothe chassis.

As described in more detail herein, the chassis supports the modulessuch that the modules in the module stack do not directly engage oneanother. For example, the modules are spaced apart from one another byclearance gaps 510 defined between adjacent modules in the stack. Forexample, a given clearance gap is defined between the bottom side of anupper module in an adjacent pair of modules and the top side of a lowermodule in the adjacent pair. The clearance gaps enable the flow of airbetween the modules for dissipating heat and for restricting and/orprohibiting the spread of fire and/or thermal runaway between modules.The clearance gaps also enable the modules to be independently removedone at a time in any order, as the lower modules in the stack do notsupport the weight of upper modules in the stack. Although not clearlyshown in FIG. 10, even the lowermost, first module 204A may be spacedapart from the support platforms by a clearance gap when the firstmodule is fully loaded in the module stack. The first module maytemporarily engage and slide along the support members while loading andunloading the first module, but is configured to separate from thesupport members before achieving a fully loaded position, as describedin more detail herein.

In an embodiment, the electrical power delivery system 200 also mayinclude a support member 512 that is spaced apart from the back wall506. The support member is mechanically coupled to multiple modules inthe stack, and is configured to provide stiffening support for themodules. The support member in the illustrated embodiment is coupled tothe modules at the front sides 310 thereof, such as via bolts and nutsor other fasteners. The support member may be or include a metal anglethat extends along two orthogonal planes, and couples to each of themodules at a corner between the front side of the module and theconnector side 320 of the module. The support member may tether themodules together to reduce movements of the modules relative to eachother. For example, the support member may stiffen the module stack tomaintain the size of the clearance gaps when exposed to applied forces,such as vibrations, accelerations, and impact forces, during movement ofthe vehicle on which the electrical power delivery system is disposed.Furthermore, the support member may be electrically conductive, and maybe used to provide an electrical grounding path. For example, thesupport member may connect grounding elements of each of the modules tothe chassis to electrically common and ground the grounding elements.

FIG. 11 is a front perspective view of the electrical power deliverysystem 200 according to an embodiment. In the illustrated embodiment,the electrical power delivery system 200 may include a case 600. Themodule stack 202, the bus bar 206, and the energy storage devices 208are commonly housed within the case. The chassis 504 (shown in FIG. 10)may also be housed within the case. The case has a box shape withseveral walls including a front wall 602, two opposing side walls 604, abottom wall 606 under the support platforms 508, a top wall (not visiblein FIG. 11), and a back wall 608 opposite the front wall. Several of thewalls including the front and two side walls define windows 610therethrough for accessing the components within the case and/orpermitting air flow through the case. The case optionally may haveadditional windows and/or other types of openings to ensure air flowthrough the case and reduce weight. The case may enable the electricalpower delivery system to be moved as a single, modular unit. The casemay also protect the components of the system from damage from externalimpacts as well as debris and contaminants. Alternatively, instead ofbeing housed within the case, the chassis may be integrated into thecase as an integral portion of the case.

FIG. 12 is a front perspective view of the electrical power deliverysystem 200 shown in FIG. 11 with the module stack omitted according toan embodiment. The bus bar 206 may be mounted to the case 600 and/or thechassis 504 via one or more mounting brackets 612. In the illustratedembodiment, the vertically-oriented bus bar is coupled to mountingbrackets at both the top and bottom ends of the bus bar. In anembodiment, the back wall 506 of the chassis defines slots 614therethrough. The slots are configured to align with the rear plenumopenings 334 of the modules 204 (shown in FIG. 5) when the modules aremounted to the chassis to permit air flow across the back wall into themodules for cooling the internal electrical components therein.

FIG. 13 is a perspective view of a mounting system 700 for mountingmodules in a module stack according to an embodiment. The mountingsystem 700 may be used for mounting the modules 204 of the electricalpower delivery system 200 in the module stack 202, as shown in FIGS. 2and 10. The mounting system is not limited to use with the modules 204of the electrical power delivery system 200, however, as the mountingsystem may be used to mount other types of modules, such as servermodules in a server rack, drawers in a cabinet or article of furniture,and/or the like.

The mounting system may include a chassis 702, multiple guide rods 704,and multiple lifting elements 706. The modules that are mounted may alsorepresent components of the mounting system. No modules are shown inFIG. 13. The chassis may include a back wall 708 and at least onesupport platform 710. The chassis has two support platforms 710 in theillustrated embodiment. The chassis may be the same or similar to thechassis 504 shown in FIG. 10, such that the back wall 708 represents theback wall 506, and the two support platforms 710 represent the supportplatforms 508.

The guide rods 704 may mechanically align and guide the mounting of themodules to the chassis. For example, the guide rods may engage themodules to ensure that the modules properly align with the chassis asthe modules are loaded onto the chassis. The guide rods are mechanicallycoupled to the back wall 708. The guide rods project from a front side712 of the back wall. The front side faces towards the modules in thestack (when the modules are mounted). The guide rods are suspended abovethe support platforms. The guide rods are cantilevered to extend from afixed end 714 at the back wall to a distal end 716 that is spaced apartfrom the back wall and supported in space by the rigidity of the guiderod. The guide rods may be secured in place through holes in the backwall via fasteners (such as nuts, rivets, and/or the like), punchriveting, spot welding, or the like. In the illustrated embodiment, theguide rods are arranged in two vertical columns 718. One of the guiderods in each column aligns with a corresponding guide rod in the othercolumn to define a pair of rods. Each pair of rods is associated with adifferent module of the modules in the module stack. The two verticalcolumns are arranged on opposite sides of slots 720 defined through theback wall. The slots 720 may represent the slots 614 of the back wall506 shown in FIG. 12. The slots 720 enable air flow through the backwall. The guide rods may have a rigid composition, such as including oneor more metals. In an embodiment, the guide rods are threaded withhelical threads. The guide rods of the mounting system may be replicasor copies of one another, such that the guide rods have a common size,shape, composition, and the like. Although the guide rods are arrangedin two columns in the illustrated embodiment, in an alternativeembodiment the guide rods may be arranged in a single column or at leastthree columns.

The lifting elements 706 are components mounted at or proximate to theback wall. The lifting elements are configured to mechanically engage(in direct physical contact) the modules during the mounting process.More specifically, the lifting elements are configured to at leastpartially support the weight of the modules when the modules achieve afully loaded position relative to the chassis. The lifting elements mayalso contribute to the assembly of the electrical power delivery systemby ensuring that the modules align with corresponding components thatcouple to the modules, such as the vertical bus bar 206, electricalconnectors, side walls of the chassis, the support member 512, and/orthe like. Without the lifting elements, the modules may not properlyalign with such components.

In the illustrated embodiment, the lifting elements are mechanicallycoupled to the back wall and are spaced apart from the guide rods. Forexample, each lifting element in FIG. 13 is discretely and independentlycoupled to the back wall. The lifting elements may be coupled to theback wall via fasteners (such as nuts, rivets, and/or the like), punchriveting, spot welding, or the like. The lifting elements are optionallyarranged in two vertical columns that are colinear with the columns ofthe guide rods. Like the guide rods, the lifting elements of thedifferent columns may align in pairs. To support the modules, thelifting elements may have a rigid composition that may include one ormore metals. The lifting elements in the illustrated embodiment projectfrom the front side of the back wall shorter lengths than the guiderods. The lifting elements shown in FIG. 13 are also referred to hereinas pins.

FIG. 14 is a side cross-sectional view of the mounting system 700showing a first module 722 of a module stack poised for mountingaccording to an embodiment. The first module 722 may represent thelowermost module 204A shown in FIGS. 2 and 10. The cross-section istaken along a plane that extends through one of the columns 718 of theguide rods 704 and lifting elements 706, as well as through a portion ofa housing 724 of the module 722. The housing 724 defines at least onechannel 726 configured to receive a corresponding one of the guide rodstherein. In the illustrated embodiment shown in FIGS. 13 and 14, thehousing may define two channels, with each of the two channelsconfigured to receive a different one of the two guide rods in acorresponding pair. Only one of the channels is shown in FIG. 14. Thechannel that is not visible in FIG. 14 receives a guide rod from theother column therein. The channels extend along a length of the module722 between a rear side 728 and a front side 730 thereof. Each channelhas a rear opening 732 at the rear side. The channels optionally extendfully from the rear side to the front side and include front openings734 at the front side. Alternatively, the channels do not extend fullyto the front side, such that the front openings to the channels areaxially located between the rear side and the front side.

In an embodiment, the module is configured to be loaded in a loadingdirection 736 relative to the chassis 702 for mounting the module. Theloading direction is towards the back wall 708. The weight of the modulemay be supported in whole or at least in part by the support platforms710. For example, a bottom side 738 of the module is disposed on (e.g.,in directed engagement with) a top surface 740 of the support platforms.The module may be passively moved in the loading direction by receivingan external force. For example, a human operator may grasp a handle on ashelf 742 of the module to push the module in the loading direction 736towards the back wall. Optionally, a machine (e.g., a robot) may beprogrammed to push the module. The bottom side of the module may slidealong the support platforms towards the back wall. For example, theforce exerted on the module may be sufficient to exceed the resistanceattributable to static friction between the module and the top surfaceof the support platforms. The mechanical support provided by theplatforms may reduce the amount of force required to load the modulerelative to the human operator and/or machine lifting and carrying themodule in the loading direction. In a non-limiting example, the modulemay be relatively heavy for a person to carry, such as between 50 and150 pounds (lbs.) (e.g., 22 to 68 kg). In the illustrated embodiment,the support platforms project outward away from the back wall beyond thedistal ends 716 of the guide rods 704, which allows a rear portion ofthe module to be placed on the support platforms prior to the guide rodsbeing received within the channels 726.

During assembly of the module stack, the rear portion of the module maybe rested on the support platforms before making any necessaryadjustments to the module to align the channels with the correspondingguide rods. Once the channels are aligned with the guide rods, themodule is slid on the support platform in the loading direction to causethe guide rods to enter the corresponding channels of the module. Therear openings 732 of the channels may define sloped lead-in sections 744to reduce the risk of stubbing between the distal ends of the guide rodsand the rear openings. For example, the diameter of each channel mayconically taper from the rear opening at the rear side inward (in adirection towards the front side) along the sloped lead-in section.

The guide rods of a lowermost pair of guide rods are disposed adesignated height above the support platforms, and the channels of themodule are disposed the designated height above the bottom side of themodule, to enable the guide rods to be received into the correspondingchannels while the bottom side of the module is supported by the supportplatforms. The interaction between the guide rods and the channels mayguide the module towards the back wall in proper alignment with thechassis as the module is moved in the loading direction. For example,the guide rods are oriented parallel to the loading direction. In anembodiment, the support platforms support an entirety or at least amajority of the weight of the module during an initial stage of loadingthe module towards the back wall. For example, the guide rods may notsupport any of the weight, or may only support a small percentage (e.g.,less than 10%) of the weight, while the module rests on the supportplatforms.

FIG. 15 is a side cross-sectional view of the mounting system 700showing the first module 722 at a first intermediate loading positionrelative to the chassis 702 according to an embodiment. In theillustrated embodiment, the module is disposed closer to the back wall708 than at the initial position shown in FIG. 14 due to being forced toslide along the support platforms 710 in the loading direction 736.Prior to abutting the back wall, the module engages at least one of thelifting elements 706. As described above, the lifting elements 706 inthe illustrated embodiment are pins mounted on the back wall. The pinsare arranged in pairs such that adjacent pairs are vertically spacedapart. The illustrated pin in FIG. 15 that engages the module is a firstpin 706A (e.g., a first lifting element). The other pin in the pair withthe first pin is concealed by the first pin and thus not visible in FIG.15.

The housing 724 of the module may define at least one receptacle 746along the rear side 728. The at least one receptacle may be spaced apartfrom the channels 726. For example, an intervening portion 748 of thehousing separates each receptacle from a nearby channel. Based on thearrangement of the pins in pairs as shown in FIG. 13, the module maydefine two receptacles at the rear side, such that each of thereceptacles receives a different one of the pins of the pair thereinupon the module reaching the pins. The guidance and alignment providedby the guide rods 706 within the channels 726 may enable the receptaclesof the module to align with the corresponding pins on the back wall,preventing (or at least reducing the likelihood of) stubbing.

In an embodiment, the module remains supported by the support platformsupon making initial physical contact with the pins. Thus, the module mayslide along the support platforms in the loading direction from theposition shown in FIG. 14 to the position shown in FIG. 15. The diameterof each channel 726 (e.g., even at the narrowest segment thereof) may begreater than a diameter of the corresponding guide rod 704 receivedtherein to define an open clearance area between the guide rod andinterior surfaces of the channel. In FIG. 15, while the module issupported on the support platforms, the guide rod is disposed within anupper area of the channel, and an open clearance area 750 is definedwithin the channel below the guide rod.

In an embodiment, once a distal end segment 754 of each of the guiderods within the channels of the module are accessible through the frontopenings 734 of the channels, fasteners 752 may be coupled to the distalend segments. The distal end segments extend to the respective distalends 716 of the guide rods. The fasteners are releasably coupled to theguide rods to secure the module to the chassis by preventing the modulesfrom moving in a direction opposite the loading direction relative tothe chassis. The fasteners may apply a clamp force in the loadingdirection on the housing of the module. In an embodiment, the guide rodsare helically threaded, and the fasteners are internally-threaded nutsthat can be threadably coupled to the guide rods. The fasteners may alsoinclude washers that are sandwiched between the nuts and the engagementsurface of the housing. The nuts and washers may exert the clamp forceby torqueing the nuts to axially move the nuts towards the back wallrelative to the guide rods. Optionally, the fasteners may also be usedin the mounting process to assist in moving the module from the positionshown in FIG. 15 to a fully loaded position in which the module abutsagainst the back wall. In other embodiments, the fasteners may includeor represent one or more of clips, posts, clamps, or the like.

FIG. 16 is an enlarged cross-sectional view of a portion of the mountingsystem 700 shown in FIG. 15. Although the following descriptionspecifically identifies and describes the elements shown in FIG. 16, thedescription may apply to similar elements not visible in FIG. 16. Forexample, FIG. 16 may show one guide rod 704 and one pin 706 disposedwithin the same vertical column interacting with the module 722, thedescription may also apply to the associated guide rod and theassociated pin in the other vertical column (as shown in FIG. 13). Asthe module approaches the back wall 708, the pin 706 engages the moduleto define an angled contact interface 760 between the pin and themodule. The angled contact interface passively lifts the module off thesupport platforms 710 (shown in FIG. 15) responsive to additionalmovement of the module in the loading direction. For example, the angledcontact interface is sloped or ramped transverse to the plane of thesupport platforms. The angled contact interface converts lateralmovement of the module in the loading direction (parallel to the planeof the support platforms) into vertical movement of the module away fromthe support platforms.

One or both of the pin and the housing 724 of the module define rampsurfaces that represent portions of the angled contact interface. Forexample, in the illustrated embodiment, the pin has a ramp surface 762that defines at least a portion of the angled contact interface. Theramp surface is defined along a tapered distal end segment 764 of thepin. The tapered distal end segment 764 may have a conical shape. Acontact surface 766 within the receptacle 746 of the module slides alongthe ramp surface as the module moves relative to the pin. The angle ofthe ramp surface converts the lateral movement of the module intovertical movement away from the support platforms.

A rear opening 768 of the receptacle at the rear side 728 of the housingmay be countersunk to provide an expanded lead-in area to prohibitstubbing on the pin. In the illustrated embodiment, the countersunkportion 770 has a sloped angle that is greater than the angle of theramp surface. As a result, the module is not lifted by the pin until theramp surface of the pin engages an inside edge of the module thatseparates the countersunk portion from a main portion 772 of thereceptacle. The inside edge represents the contact surface 766 of themodule in the angled contact interface. For example, as the module movesin the loading direction, the inside edge contacts and slides along theramp surface of the pin.

In an alternative embodiment, the sloped surface along the countersunkportion 770 may represent the contact surface in addition to the insideedge. For example, the ramp surface of the pin may contact and slidealong the sloped surface of the countersunk portion to provide the lift.In another alternative embodiment, the receptacle of the module does notdefine a countersunk portion, and a top surface of the receptacle at therear opening represents the contact surface that engages the rampsurface of the pin. In yet another alternative embodiment, the pin doesnot have the ramp surface, and the angled contact interface is providedby the sloped surface of the countersunk portion of the receptacle. Forexample, an edge of the pin may engage and slide along the slopedsurface of the countersunk portion as the pin is received within thereceptacle to lift the module.

In the illustrated embodiment, the pin has an intermediate section 774disposed axially between the back wall and the tapered distal endsegment. A surface 776 of the intermediate section (e.g., anintermediate surface) is between the ramp surface and the back wall. Theintermediate surface has a uniform height (or distance) above thesupport platforms along the length of the intermediate segment. Forexample, the intermediate section may be a cylindrical portion that hasa central axis parallel to the plane of the support platforms, and theintermediate surface is an exterior surface of the cylinder facing awayfrom the support platforms. When the contact surface of the moduleengages and slides along the ramp surface, the ramp surface causes themodule to gradually vertically rise away from the support platforms withadditional movement in the loading direction. Once the contact surfaceof the module moves beyond the ramp surface, the contact surface engagesand moves along the intermediate surface. Because the intermediatesurface is parallel to the support platforms, the rear end of the modulemay remain at a constant height above the support platforms as thecontact surface slides along the intermediate surface.

Therefore, according to at least one embodiment, the mounting system isdesigned such that the module being loaded laterally moves parallel tothe support platforms during an initial loading stage in which themodule is supported by the support platforms. Then, the module graduallyrises upward off the support platforms during a secondary loading stagein which the module moves both laterally and vertically. Finally, beforeengaging the back wall of the chassis, the module once again laterallymoves parallel to the support platforms due to the intermediate surface.In an alternative embodiment, the pin does not have the intermediatesection, and the ramp surface extends fully to the back wall or to arear end of the pin.

FIG. 17 is an enlarged cross-sectional view of the portion of themounting system 700 shown in FIGS. 15 and 16 showing the module 722during a secondary loading stage in which the module moves bothlaterally and vertically relative to the chassis 702. In the illustratedposition, the contact surface 766 of the module within the receptacle746 engages the ramp surface 762 of the pin 706 proximate to theintermediate surface 776. Due to the angled contact interface 760between the contact surface of the module and the ramp surface of thepin as the module is moved in the loading direction towards the backwall 708, the module is lifted by the pin off the support platforms 710.In the illustrated embodiment, the bottom side 738 of the module isspaced apart from the top surface 740 of the support platforms by a gap778 (e.g., a clearance gap). The gap indicates that the module is notsupported by the support platforms in the illustrated position of themodule. Additional evidence of the vertical movement of the modulerelative to the chassis is that the guide rod 704 is disposed lower inthe channel 726 in FIG. 17 relative to the pre-lifted position shown inFIG. 16. For example, the guide rod 704 is centered within the channelin FIG. 17, but is off-center and near a top region of the channel inFIG. 16.

In an embodiment, the module may include a gasket 780 mounted to therear side 728 of the housing 724. The gasket 780 may be the plenumgasket 338 shown in FIG. 5. The gasket is compressible and may becomposed of an elastic material, such as silicone, neoprene, rubber(e.g., natural or synthetic), and/or the like. The gasket can becompressed between the rear side of the module and the back wall whenthe module is in a fully loaded position relative to the chassis. Tinthe compressed state, the gasket may dampen vibrations. The gasket isspaced apart from the back wall in FIG. 17. For example, to preventdamage and stress on the gasket due to shearing forces, the gasket maynot engage the back wall while the module is moving vertically. Thepresence of the intermediate surface 776 ensures that the module onlymoves laterally (e.g., perpendicular to the plane of the back wall 708)when the gasket is in contact with the back wall.

FIG. 18 is a cross-sectional view of the mounting system 700 shown inFIGS. 15 through 17 showing the module 722 in a fully loaded positionrelative to the chassis 702 according to an embodiment. In the fullyloaded position, the module abuts against the back wall 708 of thechassis. The gasket 780 shown in FIG. 17 is not visible in FIG. 18 dueto the compression of the gasket between the rear side 728 of the moduleand the back wall. The module is fully separated from the supportplatforms 710 by the gap 778. In the illustrated embodiment, no portionof the module or the support platforms bridges the gap such that anentirety of the module is spaced apart from the support platforms. Theweight of the module is supported by the back wall, the pins 706 in thereceptacles 746, and/or the guide rods 704 in the channels 726.

The module may achieve the fully loaded position upon the modulesquaring up against the back wall such that the channel 726 is orientedapproximately perpendicular (e.g., within a designated tolerance marginsuch as within 1°, 3°, or 5°) to the plane of the back wall. The modulemay be moved from the position shown in FIG. 17 to the fully loadedposition shown in FIG. 18 by tightening the fastener 752 to exert aclamp force on the housing 724 in the loading direction that moves themodule. In an embodiment in which the fastener is a threaded nut, thenut may be torqued to rotate the nut, causing the fastener to push ashoulder 782 of the housing at or proximate to the front side 730towards the back wall. In reaction to the clamp force, the normal forceexerted by the back wall in the direction opposite the loading directionmay cause the module to square up against the back wall. In analternative embodiment, the module may be moved to the fully loadedposition by manually pushing the module in the loading direction untilthe module squares up against the back wall, and then tightening thefastener to secure the module in the fully loaded position. The fullweight of the module may be supported by the combination of forcesincluding the clamp force exerted by the fastener on the housing, thenormal force exerted by the back wall on the housing, and the forceexerted by the pins on the receptacles of the housing.

FIG. 19 is a side cross-sectional view of the mounting system 700showing the first module 722 in the fully loaded position and a secondmodule 802 poised for mounting according to an embodiment. The secondmodule 802 may represent the second-from-lowest module 204B in the stack202 shown in FIGS. 2 and 10. The second module may include a housing 804that may have the same or at least a similar form factor as the housing724 of the first module 722. For example, the housing 804 defines twochannels 806 that receive a corresponding pair of the guide rods 704therein, and defines two receptacles 808 that receive a correspondingpair of the pins 706. The second module may also include a gasket 814mounted on a rear side 816 of the housing, similar to the gasket 780(shown in FIG. 17) on the first module. The second module 802 isdisposed above the first module 722 in the stack such that the firstmodule is between the second module and the support platforms 710.

During the initial stages of loading, the second module may be supportedby the first module. For example, a bottom side 810 of the second modulemay be placed in physical contact on a top side 784 of the first module.The first module functions like the support platforms, as the firstmodule may support an entirety or at least a majority of the weight ofthe second module. In the illustrated embodiment, the second module issupported on the shelf 742 of the first module. The shelf is coplanarwith and/or defines an extension of the top side of the first module.The second module is then moved by an operator or a machine in theloading direction towards the back wall 708 such that the second moduleslides along the top side of the first module. The mounting of thesecond module is similar to the mounting of the first module. Forexample, once the pins engage the second module at an angled contactinterface, the second module begins to lift off the first module withadditional movement of the second module in the loading direction.

FIG. 20 is a cross-sectional view of the mounting system 700 showingboth the first and second modules 722, 802 in the fully loaded positionrelative to the chassis 702 according to an embodiment. When the secondmodule achieves the fully loaded position against the back wall 708, thesecond module may be secured in the fully loaded position via a fastener812. As shown in FIG. 20, the second module in the fully loaded positionis supported by the pins 706 in the receptacles 808, the clamp forceexerted on the housing 804 by the fastener 812, and/or the normal forceexerted by the back wall on the rear side 816 of the housing. The gasket814 may be compressed between the back wall and the rear side to providevibration dampening. The second module is spaced apart from the firstmodule below by a gap 820 defined between the bottom side 810 of thesecond module and the top side 784 of the first module. Optionally, noneof the weight of the second module is supported by the first module whenthe second module is mounted to the chassis in the fully loadedposition.

Additional modules of the module stack may be mounted to the chassis inthe same way as the second module 802. For example, a third moduleimmediately above the second module (e.g., the module 204C shown inFIGS. 2 and 10) may be loaded by sliding the third module along a topside 822 of the second module in the loading direction until the thirdmodule is lifted off the second module by the engagement with the pins706 in the third-from-lowest pair on the chassis. In this way, themodule stack is assembled one by one from the bottom up.

FIG. 21 is a side view of the mounting system 700 showing four modulesmounted to the chassis 702 in a module stack 828 according to anembodiment. The four modules include the first module 722, the secondmodule 802, a third module 830 above the second module, and a fourthmodule 832 above the third module 830. The fourth module is theuppermost module in the stack. All four modules are mounted in the fullyloaded position relative to the chassis. In an embodiment, when themodule stack is fully assembled as shown in FIG. 21, each of the modulesis spaced apart from the adjacent modules in the stack (and from thesupport platforms 710) via clearance gaps. For example, the first moduleis separated from the support platforms 710 by the gap 778 and isseparated from the second module above by the gap 820. The third moduleis separated from the second module below by a gap 834 and from thefourth module above by a gap 836.

The side view shown in FIG. 21 illustrates several aspects of themounting system 700. For example, the clearance gaps between the modulesprovide electrical, mechanical, and thermal isolation between themodules. The modules may have internal electrical components thatgenerate heat. The clearance gaps allow cooling fluid to flow betweenthe modules enabling the cooling fluid, such as air, a liquid, oranother type of gas, to absorb and dissipate heat from the system. Thegaps are also useful to prevent or at least restrict the spread ofthermal energy between the modules. For example, if one of the modulesexperiences fire and/or thermal runaway, the gaps may restrict thespread of the fire and/or thermal runaway to adjacent modules, which mayreduce the total amount of damage and loss caused by the fire and/orthermal runaway. The gaps may also enable the presence of air or anotherdielectric material that electrically insulates the modules from oneanother. The electrical insulation may reduce the influence ofelectromagnetic interference across the modules, which may improve theperformance of the internal electronic components of the modules. Themechanical isolation provided by the clearance gaps enables individuallyand independently unloading any of the modules in the stack with asimilar and limited amount of effort. For example, if the first module722 is suspected to be malfunctioning, an operator can remove the firstmodule 722 from the stack to perform maintenance without removing thethree modules above. Without the clearance gaps above the first module,the weight of the three modules above may be exerted on the top of thefirst module. In such a design that lacks the gaps, all three of themodules above may have to be removed from the stack to access thedesired first module.

The sizes of the gaps between the modules may be selected and/orcustomized to provide a desired amount of thermal and/or electricalisolation between the modules. For example, the height of the gaps maybe increased to provide additional electrical isolation between themodules. In another example, the height of the gaps may be increased ifthere is a significant risk of fire to reduce the likelihood ofsecondary damage to other modules in the stack. The gaps all have thesame sizes as one another in the illustrated embodiment, but at leastsome of the gaps may have different sizes from one another in analternative embodiment. For example, if the fourth module 832 has agreater risk of fire, is a greater producer of electromagneticinterference, and/or is more sensitive to electromagnetic interferencethan one or more of the other modules in the stack, the gap 836 betweenthe fourth module 832 and the third module 830 may be sized greater thanthe gaps between the other modules to provide increased isolation. Thesize of the gaps may be controlled by the positioning of the liftingelements (e.g., pins) and guide rods on the back wall 708.

Optionally, after mounting the modules to the chassis, one or moreinserts may be installed into the gaps. The inserts may include orrepresent vibration-dampening inserts to reduce relative movementbetween the modules, cooling inserts to provide active and/or passivecooling, fire suppression inserts, and/or the like. The inserts may havevarious forms, including pads, foam, sheets, or the like. Optionally,the inserts may occupy only a portion of the gaps to maintainpassageways for air and/or the like. Vibration dampening may also beachieved by gaskets mounted between the back wall and the rear sides ofthe modules (e.g., the gaskets 780, 814) and/or the rigid support member512 shown in FIG. 10 that mechanically couples the modules together ator near the front ends of the modules.

In an alternative embodiment, instead of sliding each of the modules onthe support platform or module below while loading and unloading themodule, the modules may be outfitted with rolling elements along therespective top sides or bottom sides thereof. The rolling elements mayinclude wheels, cylindrical rollers, or the like. The presence of therolling elements may reduce the resistance caused by friction whileloading and unloading the modules. In an embodiment, even with therolling elements, the modules completely lift off the support platformand/or module below upon achieving the fully loaded position. The liftdefines the clearance gaps. For example, the angled contact interfacemay cause the modules to lift to such an extent that the rollingelements separate from the contacting surface.

FIG. 22 is a cross-sectional view of the mounting system 700 accordingto a first alternative embodiment showing a first intermediate loadingstage of the first module 722. The first module is supported by thesupport platforms 710. In the illustrated embodiment, the liftingelements of the chassis 702 are mounted on the guide rods 704 instead ofbeing spaced apart from the guide rods and mounted directly to the backwall 708. For example, the lifting elements may be washers 902 that havea conical shape. The conical washers may annularly surround the guiderods. The conical washers are located at least proximate to the backwall, and optionally may be disposed in contact with the back wall. Theexterior surfaces of the washer are sloped to define a ramp surface 904that represents a portion of an angled contact interface that lifts themodule off the support platform. For example, as the module is moved inthe loading direction towards the back wall, the conical washereventually engages a sloped contact surface 905 along the lead-insection 744 of the channel 726 (at the rear opening 732). The rampsurface 904 of the conical washer and the contact surface 905 of thelead-in section may have complementary angles and may define the angledcontact interface.

FIG. 23 is a cross-sectional view of the mounting system 700 accordingto the alternative embodiment shown in FIG. 22 showing a secondintermediate loading stage of the first module 722. In the illustratedembodiment, a fastener 906 is installed on the distal end segment 754 ofthe guide rod 704 before the module is moved to the fully loadedposition. The fastener 906 in the illustrated embodiment is a setincluding a conical washer 908 and a threaded nut 910. The conicalwasher 908 may be a replica or copy of the conical washer 904. Theconical washer 904 proximate to the back wall may be referred to as arear lifting element or rear conical washer, and the conical washer 908engaging the nut 910 may be referred to as a front lifting element orfront conical washer. The front conical washer may mirror the rearconical washer. The front conical washer is axially disposed between thenut and the rear conical washer. Although shown as two discreteelements, the fastener in an alternative embodiment may be a unitary,one-piece, monolithic component that combines the functionality of theconical washer and the threaded nut, such as a threaded conical nut. Aramp surface 912 of the front conical washer may engage a sloped contactsurface 914 at the front opening 734 of the channel 726. In anembodiment, the module is moved from the position shown in FIGS. 22 and23 to the fully loaded position by using the fastener 906 to exert aclamp force on the module.

FIG. 24 is a cross-sectional view of the mounting system 700 accordingto the alternative embodiment shown in FIGS. 22 and 23 showing the firstmodule 722 at the fully loaded position. Applying a torque on the nut910 rotates the nut and moves both the nut and the front conical washer908 towards the back wall 708 relative to the guide rod 704. As aconsequence, the ramp surface 912 of the front conical washer wedgesunder the contact surface 914 of the module which causes the module tomove further in the loading direction and also assists with lifting afront end 916 of the module off the support platforms 710. For example,the clamp force exerted by the fastener 906 on the module and theresulting normal force exerted by the back wall on the rear side of themodule may provide a majority of the lift of the front end of themodule. The additional movement of the module in the loading directioncauses the rear conical washer 904 to lift a rear end 918 of the moduleoff the support platform. The end result is the formation of theclearance gap 778 between the module and the support platform. Theconical washers optionally may include a compressible material, such asa rubberized coating, that provides vibration dampening. The additionalmodules above the first module are mounted in a similar fashion as thefirst module.

In another alternative embodiment, the lifting elements of the mountingsystem may include both the pins shown in FIGS. 13 through 20 and thefront conical washers shown in FIGS. 22 through 24. For example, thefasteners 752 shown in FIG. 15 may include a conical washer similar tothe front conical washer 908.

FIG. 25 is a cross-sectional view of the mounting system 700 accordingto a second alternative embodiment showing an intermediate loading stageof the first module 722. The first module is supported by the supportplatforms 710 in the illustrated intermediate loading stage. FIG. 26 isa cross-sectional view of the mounting system 700 according to thealternative embodiment shown in FIG. 25 showing the first module 722 atthe fully loaded position. In the illustrated embodiment, the liftingelements are wedge members. For example, the support platforms 710include respective wedge members 950 (only one of which is visible inthe illustrated cross-section). The wedge member 950 is disposed atleast proximate to the back wall 708. For example, the wedge member isspaced apart from the back wall in the illustrated embodiment, the wedgemember optionally may contact the back wall. The wedge member mayinclude a ramp surface 952 that is sloped transverse to the plane of the(remainder of the) support platform.

As shown in FIG. 25, the bottom side 738 of the module slides along thesupport platform as the module is moved in the loading direction towardsthe back wall. Eventually, a corner 954 of the module between the bottomside and the rear side 728 engages the ramp surface of the wedge member,which defines an angled contact interface between the lifting elementand the module. Referring now to FIG. 26, additional movement of themodule causes the wedge member to passively lift the module above theplane of the remainder of the support platform. A fastener 956 iscoupled to the guide rod 704 to provide a clamp force that secures themodule in sustained engagement with the back wall, allowing the frontend 916 of the module to be suspended above the support platforms todefine a clearance gap 958. Although the rear end 918 of the moduleremains in contact with the support platform via the wedge member, amajority of the bottom side of the module is spaced apart from thesupport platform to enable the formation of the gap.

In the illustrated embodiment, the first module may include a wedgemember 960 that projects beyond the top side 784. The wedge member ofthe first module may have the same configuration or at least a similarconfiguration (e.g., size and shape) as the wedge member 950 of thesupport platform. The wedge member of the first module passively liftsthe second module 802 off the top side of the first module when thesecond module is being loaded in the module stack.

FIG. 27 is a perspective view of a portion of the electrical powerdelivery system 200 shown in FIG. 2. The illustrated portion of theelectrical power delivery system shows the electrical energy storagedevices 208, which are capacitors in the illustrated embodiment. Theelectrical power delivery system is oriented with respect to a lateralaxis 1001, a height axis 1002, and a longitudinal axis 1003. The axes1001-1003 are mutually perpendicular. The axes 1001-1003 are notrequired to have any particular orientation with respect to gravity,although in at least one embodiment the height axis 1002 extends in avertical direction parallel to the force of gravity.

The capacitors are mechanically and electrically connected to theconductive bus bar (or conductive plane) 206, and commonly project fromthe second side 220 of the bus bar facing away from the module stack202. The capacitors may be cylindrical and extend along respectivecentral axes 222 from a respective connection end 1006 to a respectivedistal end 1008 opposite the connection end 1006. The connection endsare disposed at the bus bar and are electrically and mechanicallyconnected thereto. The distal ends are spaced apart from the bus bar.Thus, the capacitors are cantilevered from the bus bar. As describedabove, the central axes of the capacitors may be perpendicular to theplane 214 of the bus bar. The plane 214 may be oriented parallel to theheight axis 1002. The capacitors may project laterally from the bus bar,such that the central axes 222 are parallel to the lateral axis 1001.

In one or more embodiments, the electrical power delivery system mayinclude at least one support structure 1004 that supports portions ofthe capacitors and/or other electrical energy storage devices that arespaced apart from the conductive bus bar. The support structures arespaced apart from the conductive bus bar. The support structures mayengage portions of the capacitors that are disposed between theconnections ends and the distal ends to provide structural support forthe capacitors. The support structures engage and at least partiallysurround each of the capacitors in the array. In the illustratedembodiment, the electrical power delivery system may include two supportstructures. Each of the support structures engages and at leastpartially surrounds the four capacitors in a different column of twoadjacent columns of the capacitors. In an alternative embodiment, theelectrical power delivery system may have a different number of supportstructures than the two shown in FIG. 27.

The support structures can support a load to reduce forces exerted atthe connection ends of the capacitors where the capacitors are connectedto the bus bar. For example, the load supported by the supportstructures may include a portion of the weight of the capacitors. In anon-limiting example, the capacitors may each weight at least fivepounds, such as ten pounds, so the structural support provided by thesupport structures at locations spaced apart from the bus barsignificantly reduce (or eliminate) the torsional forces exerted at theconnection ends due to the length and weight of the capacitors. The loadsupported by the support structures may also include forces attributableto travel of a vehicle in which the electrical power delivery system isdisposed. For example, during movement and other operation of thevehicle, vibrations, accelerations, and impact forces (e.g., from uneventerrain, etc.) may be exerted on the electrical power delivery system.The support structures can prohibit or at least limit movement of thecapacitors relative to the bus bar and the other components of theelectrical power delivery system due to vibrations, accelerations,and/or impact forces during travel of the vehicle. The supportstructures may also absorb and dissipate such forces to reduce theamount of force exerted on the capacitors, relative to the electricalenergy storage devices being connected directly to the chassis. Reducingthe magnitude of forces exerted on the capacitors may improve theoperating performance and/or increase the operational lifetime of thecapacitors because high forces can damage the capacitors or theconnectors between the capacitors and the bus bar.

In one or more embodiments, the support structures mechanically supportthe corresponding capacitors along at least two support directions 1010,1012 that are orthogonal to each other. For example, a first supportdirection 1010 shown in FIG. 27 points vertically upward parallel to theheight axis 1002, to indicate that the support structure supports theweight of the capacitor (which is directed downward along the heightaxis 1002 due to the force of gravity). The second support direction1012 shown in FIG. 27 points parallel to the longitudinal or depth axis1003 and indicates that the support structure restricts movement of thecapacitor along the longitudinal axis 1003 due to vibrations,accelerations, and/or impact forces. FIG. 27 also shows a third supportdirection 1014 that is parallel to and opposite the first supportdirection 1010 along the height axis 1002. Thus, the support structuresrestrict upward movement of the capacitors due to vibrations,accelerations, and/or impact forces. The third support direction 1014 isorthogonal to the second support direction 1012. Although not indicatedin the illustrated embodiment, the support structures may also supportthe capacitors in a fourth support direction that is parallel to andopposite the second support direction 1012 along the longitudinal axis1003 (and orthogonal to the first and third support directions 1010,1014). Therefore, the structural supports support each of the capacitorsin at least one vertical direction parallel to the height axis and in atleast one longitudinal direction parallel to the longitudinal (or depth)axis (which is orthogonal to both the height axis and the lateral axis).The support directions 1010, 1012, 1014 provided by the supportstructures are within a common plane 1016. The plane 1016 is parallelto, and spaced apart from, the plane 214 of the bus bar. Optionally, thesupport structures support the capacitors in at least two orthogonalsupport directions within the plane 1016 that are not parallel to theaxes 1001-1003 in addition to, or instead of, the support directionsshown in FIG. 27.

The support structures may be secured to the chassis 504 of theelectrical power delivery system, to the case 600 (shown in FIG. 11), orto another component on the vehicle. In the illustrated embodiment, thesupport structures are fixed to a beam (or arm) 1018 of the chassis. Thebeam may mechanically support the support structures relative to thechassis by rigidly tying the support structures to the chassis. When theelectrical power delivery system is exposed to forces attributable tovibration, acceleration, and/or impacts, mechanically securing thesupport structures to the chassis reduces relative movement between thesupport structures (and the capacitors) and the chassis. In theillustrated embodiment, the beam is disposed above a top 1020 of thesupport structures, and the support structures may be coupled to thebeam via fasteners, adhesives, and/or the like. The support structuresmay be separately secured to the chassis relative to the bus bar. Forexample, the support structures are mounted to the beam of the chassisat a location spaced apart from the bus bar. In an alternativeembodiment, the support structures may be coupled to the chassis at oneor more other locations, such as at a bottom 1022 of the supportstructures or along a side of the support structures in addition to thetop or instead of the top.

FIG. 28 is a side view of the electrical power delivery system 200showing the two support structures 1004 according to the embodimentshown in FIG. 27. In the illustrated embodiment, support structuressurround at least a majority of the perimeter of each of the capacitors208 to support the capacitors in numerous support directions. Thecapacitors may be cylindrical with circular perimeters orcircumferences. The support structures in FIG. 28 surround eachcapacitor around almost the entire circumference thereof, if not theentire circumference, such that the support structures support thecapacitors in a bevy of radially-extending support directions 1024. Atleast some of the radially-extending support directions 1024 areorthogonal to one another.

In the illustrated embodiment, each support structure is an assemblythat may include a first shell member 1030 and a second shell member1032 that couple together around the capacitors to support thecapacitors. The design of the support structures may be referred to as aclamshell design. The first shell member 1030 has an inner side 1034 anddefines multiple concave grooves 1036 along the inner side. The concavegrooves are spaced apart along a height of the first shell member.Likewise, the second shell member 1032 of each support structure has aninner side 1038 and defines multiple concave grooves 1040 along theinner side that are spaced apart along the height of the second shellmember.

The support structures are shown in assembled states in FIG. 28. In theassembled state, the inner sides 1034, 1038 of the first and secondshell members face towards each other. The capacitors are received intocorresponding concave grooves 1036, 1040 of the shell members. Forexample, a given capacitor 208A is received into one concave groove1036A of the first shell member and one concave groove 1040A of thesecond shell member. The concave groove of the first shell membersurrounds a first perimeter segment of the capacitor, and the concavegroove of the second shell member surrounds a second perimeter segmentof the capacitor. The second perimeter segment may be circumferentiallyspaced apart from the first perimeter segment such that there is nooverlap between the first and second shell members. The concave groovesof the first and second shell members engage the outer surfaces of thecapacitors to support the capacitors in the radially-extending supportdirections.

When the first shell member is coupled to the second shell member, aseam 1042 may be defined between the inner sides of the first and secondshell members along portions 1044 of the shell members that border theconcave grooves. For example, some portions 1044 are disposed betweentwo concave grooves and other portions 1044 are disposed at the top 1020and the bottom 1022 of the support structure. Optionally, the innersides may be spaced apart at the seam to define a narrow gap between thetwo shell members. Alternatively, the inner sides of the shell membersmay abut against each other at the seam.

In the illustrated embodiment, each of the two support structures has avertical orientation, such that the support structures are elongatedparallel to each other and parallel to the height axis 1002 shown inFIG. 27. In an alternative embodiment, the support structures may have adifferent orientation, such as a longitudinal orientation parallel tothe longitudinal axis 1003 in FIG. 27. The longitudinal orientation maybe orthogonal to the vertical orientation that is shown. For example,the electrical power delivery system may include fourlongitudinally-extending support structures, with each support structuresurrounding two capacitors, instead of the two vertically-extendingsupport structures shown in the illustrated embodiment.

FIG. 29 is a perspective view of a portion of the first shell member1030 of one of the support structures 1004 shown in FIGS. 27 and 28according to an embodiment. FIG. 30 is a perspective view of a portionof the second shell member 1032 of the same support structure. The firstand second shell members 1030, 1032 may represent portions of either ofthe two support structures that support the array of capacitors as shownin FIGS. 27 and 28. The illustrated portions of the first and secondshell members 1030, 1032 depict an end of the support structure, such asthe top 1020.

In an embodiment, the first shell member may include rods 1050 thatproject from the inner side 1034 thereof. For example, the rods aremounted to the first shell member at the portions 1044 of the firstshell member that border the concave grooves 1036. The rods may be atleast partially embedded within the material of the first shell member.For example, the first shell member may be at least partially composedof a composite material, a plastic material, and/or the like. The rodsmay be embedded within the material by securing an end of each rod intoa hole in the material via an adhesive, an epoxy, or the like, or may beembedded in-situ during the formation of the first shell member, such asvia a molding process or the like. The rods may include a metal materialand a fastener. In one embodiment, the rods have helical threads thatcan receive a threaded nut or another threaded fastener. The rodsproject from the inner side with parallel orientations. Although tworods are shown in the illustrated portion of the first shell member, inother embodiments the entire first shell member may include more thantwo rods. The rods may be used for coupling the first shell member tothe second shell member. Other fasteners, such as clips and quickconnects may be used in other embodiments.

As shown in FIG. 30, the second shell member defines apertures 1052along the inner side 1038 thereof. Each of the apertures is sized andshaped to receive a single rod of the first shell member therein tocouple the first and second shells together. The diameters of theapertures may be slightly larger than the diameters of the rods to allowthe rods to be received within the apertures without stubbing orotherwise restricting coupling, while also providing alignment andguidance during the coupling operation. For example, the engagementbetween the rods and the interior surfaces of the apertures may providea track that guides the coupling between the two shell members as thetwo shell members move towards each other and towards the capacitorstherebetween. The apertures are positioned to align with the rods, suchthat the apertures are located at the portions 1044 of the second shellmember that border the concave grooves 1040. The apertures optionallyextend fully through an entire width of the second shell member from theinner side 1038 to an outer side 1054 of the second shell memberopposite the inner side. Optionally, the rods may project a distancefrom the first shell member than is greater than the weight of thesecond shell member such that a distal tip 1056 of each rod eventuallyexits the aperture and projects beyond the outer side of the secondshell member when the shell members are coupled together.

In one or more embodiments, the first and second shell members includecompressible liners 1060 within the respective concave grooves 1036,1040. The compressible liners 1060 can engage outer surfaces of thecapacitors when the shell members are coupled together. The compressibleliners are affixed along respective curved inner surfaces 1062 of theshell members that define the concave grooves. The liners may be affixedto the inner surfaces via adhesives, fasteners, or the like. In anembodiment, the compressible liners include a different material thanthe bodies of the shell members. For example, the compressible linersmay be less rigid and more flexible and compressible than the bodies ofthe shell members. Optionally, the liners may include or represent afoam or foam-like material, such as a silicone foam or the like. Duringthe coupling process, as the first and second shell members are movingtowards the capacitors to engage and surround the capacitors, thecompressible liners can reduce and/or more evenly spread, thecompressive forces exerted on the capacitors. For example, the linerscan compress different amounts in different places, if necessary, tomake the clamp forces exerted on the capacitors more uniform. Thecompression of the liners during coupling may also provide an inherentbenefit of self-centering of the support structure on the capacitors.

FIG. 31 illustrates a portion of one of the support structures 1004shown in FIGS. 27 through 30 in a partially assembled state according toan embodiment. To assemble the support structure, the first and secondshell members 1030, 1032 are arranged along opposite sides of thecorresponding capacitors 208 and are aligned with each other to enablethe rods 1050 to be received into corresponding apertures 1052. Theshell members are pushed towards each other, and towards the capacitorstherebetween. In an embodiment, both the first shell member and thesecond shell member can move relative to the capacitors. The shellmembers move towards each other along a coupling axis 1066. Theengagement of the rods within the apertures guide the movement along thecoupling axis and maintain alignment of the shell members. In thepartially assembled state shown in FIG. 31, the compressive liners 1060are just starting to engage outer surfaces 1068 of the capacitors.

FIG. 32 shows the portion of the support structure 1004 of FIG. 31 in afully assembled state according to an embodiment. In one or moreembodiments, once the distal tips 1056 of the rods 1050 protrude fromthe apertures along the outer side 1054 of the second shell member 1032,fasteners 1070 are coupled to the distal tips to secure the first andsecond shells together. The fasteners 1070 in an embodiment are nutsthat are threadably coupled to the threaded rods. Providing a rotationaltorque on the nuts to rotate the nuts on the rods may exert a clampforce that draws the two shell members together along the coupling axis1066 (shown in FIG. 31). The clamp force exerted by the tightening ofthe nuts may enable self-centering of the support structure around thecapacitors. For example, if there is a larger clearance between thefirst shell member and the capacitors than between the second shellmember and the capacitors, then the clamp force may cause the firstshell member to move a greater distance towards the capacitors and thesecond shell member than the distance that the second shell member movesto provide self-centering. The compressive liners 1060 may spread theclamp forces to provide relatively even compressive forces around theperimeter of the capacitors.

In an embodiment, after coupling the first and second shell memberstogether to assemble the support structure on the capacitors, theassembled support structure is then secured to the chassis 504.Optionally, the support structure can be secured to the chassis via amounting bracket 1072 that couples the top 1020 of the support structureto the beam 1018 of the chassis (shown in FIG. 27). The supportstructure may be assembled prior to securing the support structure tothe chassis to enable both shell members to move freely along thecoupling axis during the coupling process.

FIG. 33 illustrates a support structure 1100 for mechanically supportingmultiple electrical energy storage devices, such as capacitors, of theelectrical power delivery system according to a first alternativeembodiment. Two of the support structures 1100 may be used in place ofthe two support structures 1004 shown in FIGS. 27 through 32. Thesupport structure 1100 has a unitary, monolithic (e.g., one-piece) body1102 that defines multiple openings 1104 therethrough. The openingsextend fully through a thickness of the body. The openings are spacedapart along a surface area of the support structure. Each of theopenings is sized and positioned to receive a single capacitor therein.In the illustrated embodiment, the support structure has four openingsthat are arranged in different quadrants of the support structure.

To mount the support structure on the capacitors (or other energystorage devices) that project from the bus bar, the support structure ismoved in a mounting direction relative to the capacitors. The mountingdirection is oriented towards the bus bar 206 along the lateral axis1001 shown in FIG. 27, such that the distal ends 1008 are the firstportions of the capacitors received through the openings of the supportstructure. Due to the quadrilateral arrangement of the four openings,the support structure may be mounted on an upper group of fourcapacitors shown in FIG. 27 or a lower group of four capacitors. Anothersupport structure that is a replica of the illustrated structure can bemounted to the other group of four capacitors to mechanically supportall eight capacitors in the array. Alternatively, the support structure1100 could be redesigned to define eight openings sized and positionedfor mechanically supporting all eight of the capacitors using the singlesupport structure.

In the illustrated embodiment, the openings are not closed shapes (e.g.,closed circles), but rather are open at the corners 1106 of the supportstructure. The open corners may enable the body of the support structureto at least partially deflect or flex as the support structure is loadedonto the capacitors, which may provide alignment and/or self-centeringof the support structure relative to the capacitors. The supportstructure optionally may have compressible liners (not shown) alonginner surfaces 1108 of the body that define the openings. Like thesupport structures 1004, the support structure 1100 can engage and atleast partially surround the capacitors, and to mechanically support thecapacitors along at least two support directions that are orthogonal toeach other.

FIG. 34 illustrates a support structure 1200 for mechanically supportingmultiple electrical energy storage devices, such as capacitors, of theelectrical power delivery system according to a second alternativeembodiment. In the illustrated embodiment, the support structure has aunitary, monolithic (e.g., one-piece) body 1202 that defines multipledepressions 1204 along a first side 1206 of the body. The depressionsare positioned in a quadrilateral arrangement similar to the openings1104 of the support structure 1100 shown in FIG. 33. The depressionsoptionally do not extend fully through a thickness of the body. Rather,the depressions resemble craters or cavities. The depressions arepositioned and sized such that each depression receives the distal end1008 (shown in FIG. 27) of a different capacitor therein as the supportstructure is moved in the mounting direction towards the bus bar tomount the support structure on the capacitors. The depressions cup thedistal ends of the capacitors. The body of the support structure may beat least partially compressible or deflectable to dampen and/or absorbforces. For example, the body may include a compressible foam.

Like the support structure 1100, two of the support structures 1200 maybe utilized to mechanically support all eight of the capacitors.Alternatively, the support structure 1200 could be redesigned to defineeight depressions sized and positioned for mechanically supporting alleight of the capacitors using the single support structure. Like thesupport structures 1004 and 1100, the support structure 1200 can engageand at least partially surround the capacitors, and to mechanicallysupport the capacitors along at least two support directions that areorthogonal to each other.

FIG. 35 illustrates a support structure 1300 for mechanically supportingmultiple electrical energy storage devices 208, such as capacitors, ofthe electrical power delivery system according to a third alternativeembodiment. The support structure 1300 may include a rigid body 1302 andmultiple collars 1304 that are tethered to the rigid body 1302. Therigid body may be a post that is affixed to the chassis or may representa portion of the chassis. Each collar is a band that engages and wrapsaround a different one of the capacitors. The collars are tethered tothe rigid body via straps 1306. Like the support structures 1004, 1100,and 1200, the support structure 1300 may mechanically support thecapacitors along at least two support directions that are orthogonal toeach other.

In one or more embodiments, the specific type, materials, and/ordimensions of the support structure(s) used to mechanically support theelectrical energy storage devices may be selected based on expected useof the electrical power delivery system. For example, if the electricalpower delivery system is to be mounted onboard an off-road vehicle thatexperiences significant vibration and/or impact forces due to travelover uneven terrain or other operations, the type of support structure,or materials and dimensions thereof, may be selected to provide adesired amount of support to withstand such vibration and/or impactswithout damaging the energy storage devices or degrading the performancethereof. In a non-limiting example, the two-piece clamshell design ofthe support structure 1004 shown in FIGS. 27 through 32 may provide moresupport than the unitary design of the support structure 1100 shown inFIG. 33. Based on this presumption, the support structure 1004 may beselected for more rugged use applications in which greater forces areexpected to be exerted on the power delivery system, and the supportstructure 1100 may be selected for more tame use applications with lowerexpected forces on the power delivery system. Besides the selection ofthe type of support structure, the materials, dimensions, and/ormounting means of the support structure to the chassis may be customizedor selected based on the harshness of the intended use. For example, thetype and/or size of compressible liners within the support structure mayhave a selected compliancy level (or other properties) designed toabsorb and dissipate the expected magnitude of forces.

In one or more embodiments, a mounting system for mounting a module isprovided. The mounting system includes a chassis, multiple guide rods,and multiple lifting elements. The chassis includes a back wall and asupport platform. The guide rods are connected to and extend from theback wall. The guide rods are suspended above the support platform. Afirst guide rod of the guide rods is spaced a designated height abovethe support platform to enable the first guide rod to be received withina channel of the module while the module is disposed on the supportplatform. The first guide rod is configured to guide movement of themodule relative to the support platform in a loading direction towardsthe back wall. The lifting elements are disposed at or proximate to theback wall. As the module approaches the back wall, a first liftingelement of the lifting elements is configured to engage the module at anangled contact interface between the first lifting element and themodule to lift the module off the support platform responsive toadditional movement of the module in the loading direction. When themodule is in a fully loaded position relative to the chassis, the moduleis supported by the back wall, the first lifting element, and/or thefirst guide rod, and the module is spaced apart from the supportplatform by a gap.

Optionally, the first lifting element has a ramp surface that defines atleast a portion of the angled contact interface between the firstlifting element and the module such that a contact surface of the moduleslides along the ramp surface to convert lateral movement of the modulein the loading direction into vertical movement of the module away fromthe support platform. Optionally, the first lifting element has anintermediate surface disposed axially between the back wall and the rampsurface, the intermediate surface has a uniform height above the supportplatform along a length thereof. The intermediate surface of the firstlifting element engages the contact surface of the module after thecontact surface moves beyond the ramp surface as the module moves in theloading direction.

Optionally, the first lifting element is mounted on the first guide rodand has a conical shape.

Optionally, the first lifting element is mounted to the back wall at alocation that is spaced apart from the first guide rod.

Optionally, the first lifting element is a wedge member that is mountedto the support platform.

Optionally, the guide rods are cantilevered and extend from the backwall to respective distal end segments of the guide rods. The mountingsystem also includes a fastener that is configured to releasably coupleto the distal end segment of the first guide rod to exert a clamp forceon the module for securing the module to the chassis. Optionally, thefirst guide rod is threaded and the fastener is a nut configured to bethreadably coupled onto the distal end segment of the first guide rod.

Optionally, the first lifting element disposed at or proximate to theback wall is a rear lifting element, and the mounting system includes afront lifting element that is configured to be mounted to a distal endsegment of the first guide rod. The front lifting element has a conicalshape that wedges under the module to lift a front end of the module offthe support platform responsive to movement of the front lifting elementin the loading direction relative to the module.

In one or more embodiments, a mounting system is provided that includesa chassis and a first module. The chassis includes a back wall, multipleguide rods connected to and extending from the back wall, multiplelifting elements disposed at or proximate to the back wall, and asupport platform disposed below the guide rods. The first module isconfigured to be mounted to the chassis in a stack with other modules.The first module has a top side and a bottom side opposite the top side.The first module defines a channel configured to receive a first guiderod of the guide rods therein. The channel is spaced a designated heightabove the bottom side to enable the first guide rod to enter the channelwhile the bottom side is disposed on the support platform. The firstguide rod is configured to guide movement of the first module relativeto the support platform in a loading direction towards the back wall. Asthe first module approaches the back wall, a first lifting element ofthe lifting elements is configured to engage the first module at anangled contact interface between the first lifting element and the firstmodule to lift the first module off the support platform responsive toadditional movement of the first module in the loading direction. In afully loaded position relative to the chassis, the first module issupported by the back wall, the first lifting element, and/or the firstguide rod, and the bottom side of the first module is spaced apart fromthe support platform by a gap.

Optionally, the mounting system further includes a second moduleconfigured to be mounted to the chassis above the first module such thatthe first module is between the second module and the support platform.The second module is at least partially supported by the top side of thefirst module as the second module moves in the loading direction. Atleast a second lifting element of the lifting elements is configured toengage the second module at an angled contact interface between thesecond lifting element and the second module to lift the second moduleoff the first module responsive to additional movement of the secondmodule in the loading direction. In the fully loaded position, thesecond module is supported by the back wall, the second lifting element,and/or the second guide rod, and the second module is spaced apart fromthe first module by a gap.

Optionally, the second module defines a channel configured to receive asecond guide rod of the guide rods therein to guide movement of thesecond module in the loading direction. The channel is spaced adesignated height above a bottom side of the second module to enable thesecond guide rod to enter the channel while the bottom side of thesecond module is disposed on the top side of the first module.

Optionally, the mounting system further includes a support member thatis spaced apart from the back wall of the chassis and is mechanicallycoupled to both the first module and the second module to restrictmovement of the first and second modules relative to each other.

Optionally, the first module has a rear side that faces towards the backwall and a gasket mounted on the rear side. The gasket is configured tobe compressed between the rear side of the first module and the backwall when the first module is in the fully loaded position.

Optionally, the first module has a front side facing away from the backwall. The first module includes a shelf protruding from the front sideto define a front end of the first module. The shelf includes a handlethereon. The top side of the first module extends along the shelf.

Optionally, the channel of the first module includes a rear opening at arear side of the first module. The rear opening is countersunk toprovide a ramp surface. The ramp surface at the rear opening isconfigured to engage the first lifting element and define a portion ofthe angled contact interface that lifts the first module off the supportplatform.

Optionally, the first lifting element is mounted to the back wall at alocation that is spaced apart from the first guide rod. The first moduledefines a receptacle at a rear side of the first module. The receptacleis spaced apart from the channel and configured to receive the firstlifting element therein to define a portion of the angled contactinterface that lifts the first module off the support platform.

Optionally, the first lifting element is a wedge member that is mountedto the support platform. The first module includes a wedge membermounted on the top side of the first module. The wedge member on thefirst module represents a second lifting element of the liftingelements, and is configured to engage a second module being mounted tothe chassis above the first module at an angled contact interface tolift the second module off the first module responsive to additionalmovement of the second module in the loading direction.

Optionally, the guide rods are cantilevered and extend from the backwall to respective distal end segments of the guide rods. The mountingsystem also includes fasteners that are configured to releasably coupleto the distal end segments of the guide rods to exert clamp force on thefirst module and the other modules for securing the first module and theother modules to the chassis.

In one or more embodiments, a mounting system is provided that includesa module configured to be mounted to a chassis. The module includes ahousing having a top side, a bottom side opposite the top side, and arear side extending between the top side and the bottom side. The moduledefines a channel configured to receive a guide rod of the chassistherein. The channel is spaced a designated height above the bottom sideto enable the guide rod to enter the channel while the bottom side isdisposed on a support platform. Movement of the module in a loadingdirection towards a back wall of the chassis while the bottom sideengages the support platform is guided by the guide rod within thechannel. The module includes a ramp surface extending from the rear sideat a transverse orientation relative to the rear side. The ramp surfaceis configured to engage a lifting element of the chassis as the moduleapproaches the back wall to define an angled contact interface thatlifts the module off the support platform responsive to additionalmovement of the module in the loading direction relative to the liftingelement. The bottom side of the module is configured to be spaced apartfrom the support platform by a gap when the module is in a fully loadedposition relative to the chassis.

Reference is made to example embodiments of the inventive subjectmatter, examples of which are illustrated in the accompanying drawings.Wherever possible, the same reference numerals used throughout thedrawings refer to the same or like parts. Certain embodiments of theinventive subject matter are described with respect to off-highwayvehicles designed to perform an operation associated with a particularindustry, such as mining, construction, farming, etc., and may includehaul trucks, cranes, earth moving machines, mining machines, farmingequipment, tractors, material handling equipment, earth movingequipment, etc. However, the embodiments of the inventive subject matterare also applicable for use with other vehicles, such as on-roadvehicles (e.g., automobiles, tractor-trailer rigs, on-road dump trucks,etc.), rail vehicles, and marine vehicles. The embodiments of theinventive subject matter are also applicable for use with stationary,non-vehicular applications, to deliver electrical power within factoriesand other industrial settings.

To the extent that the figures illustrate diagrams of the functionalblocks of various embodiments, the functional blocks are not necessarilyindicative of the division between hardware circuitry. Thus, forexample, one or more of the functional blocks (for example, processorsor memories) may be implemented in a single piece of hardware (forexample, a general purpose signal processor, microcontroller, randomaccess memory, hard disk, and the like). Similarly, the programs may bestand-alone programs, may be incorporated as subroutines in an operatingsystem, may be functions in an installed software package, and the like.The various embodiments are not limited to the arrangements andinstrumentality shown in the drawings.

The description is illustrative and not restrictive. For example, theembodiments (and/or aspects thereof) may be used in combination witheach other. In addition, many modifications may be made to adapt aparticular situation or material to the teachings of the inventivesubject matter without departing from its scope. While the dimensionsand types of materials described herein define the parameters of theinventive subject matter, they are by no means limiting and are exampleembodiments. Many other embodiments will be apparent to one of ordinaryskill in the art upon reviewing the above description. The scope of theinventive subject matter should, therefore, be determined with referenceto the appended claims, along with the full scope of equivalents towhich such claims are entitled.

This written description uses examples to disclose several embodimentsof the inventive subject matter and also to enable one of ordinary skillin the art to practice the embodiments of inventive subject matter,including making and using any devices or systems and performing anyincorporated methods. The patentable scope of the inventive subjectmatter is defined by the claims, and may include other examples thatoccur to one of ordinary skill in the art. Such other examples arewithin the scope of the claims if they have structural elements that donot differ from the literal language of the claims, or if they includeequivalent structural elements with insubstantial differences from theliteral languages of the claims.

As used herein, an element or step recited in the singular and proceededwith the word “a” or “an” should be understood as not excluding pluralof said elements or steps, unless such exclusion is explicitly stated.Furthermore, references to “one embodiment” of the inventive subjectmatter are not intended to be interpreted as excluding the existence ofadditional embodiments that also incorporate the recited features.Moreover, unless explicitly stated to the contrary, embodiments“comprising,” “including,” or “having” an element or a plurality ofelements having a particular property may include additional suchelements not having that property. In the appended claims, the terms“including” and “in which” are used as the plain-English equivalents ofthe respective terms “comprising” and “wherein.” Moreover, in thefollowing claims, the terms “first,” “second,” and “third,” etc. areused merely as labels, and are not intended to impose numericalrequirements on their objects. Further, the limitations of the followingclaims are not written in means-plus-function format and are notintended to be interpreted based on 35 U.S.C. § 112 (f), unless anduntil such claim limitations expressly use the phrase “means for”followed by a statement of function void of further structure.

What is claimed is:
 1. A mounting system for mounting a module, themounting system comprising: a chassis including a back wall and asupport platform; multiple guide rods connected to and extending fromthe back wall, the guide rods suspended above the support platform,wherein a first guide rod of the guide rods is spaced a designatedheight above the support platform to enable the first guide rod to bereceived within a channel of the module while the module is disposed onthe support platform, the first guide rod configured to guide movementof the module relative to the support platform in a loading directiontowards the back wall; and multiple lifting elements disposed at orproximate to the back wall, wherein, as the module is moved in theloading direction, the module is configured to engage a first liftingelement of the lifting elements at an angled contact interface betweenthe first lifting element and the module, and the angled contactinterface causes the module to lift off the support platform withadditional movement of the module in the loading direction, wherein,when the module is in a fully loaded position relative to the chassis,the module is supported by one or more of the back wall, the firstlifting element, or the first guide rod, and the module is spaced apartfrom the support platform by a gap.
 2. The mounting system of claim 1,wherein the first lifting element has a ramp surface that defines aportion of the angled contact interface between the first liftingelement and the module such that a contact surface of the module slidesalong the ramp surface to convert lateral movement of the module in theloading direction into vertical movement of the module away from thesupport platform.
 3. The mounting system of claim 2, wherein the firstlifting element has an intermediate surface disposed axially between theback wall and the ramp surface, the intermediate surface having auniform height above the support platform along a length thereof,wherein the intermediate surface of the first lifting element engagesthe contact surface of the module after the contact surface moves beyondthe ramp surface as the module moves in the loading direction.
 4. Themounting system of claim 1, wherein the first lifting element is mountedon the first guide rod and has a conical shape.
 5. The mounting systemof claim 1, wherein the first lifting element is a pin that is mountedto the back wall at a location spaced apart from the first guide rod. 6.The mounting system of claim 1, wherein the first lifting element is awedge member that is mounted to the support platform.
 7. The mountingsystem of claim 1, wherein the guide rods are cantilevered and extendfrom the back wall to respective distal end segments of the guide rods,wherein the mounting system also includes a fastener that is configuredto releasably couple to the distal end segment of the first guide rod toexert a clamp force on the module for securing the module to thechassis.
 8. The mounting system of claim 7, wherein the first guide rodis threaded and the fastener is a nut configured to be threadablycoupled onto the distal end segment of the first guide rod.
 9. Themounting system of claim 1, wherein the first lifting element disposedat or proximate to the back wall is a rear lifting element and themounting system includes a front lifting element that is configured tobe mounted to a distal end segment of the first guide rod, wherein thefront lifting element has a conical shape that wedges under the moduleto lift a front end of the module off the support platform responsive tomovement of the front lifting element in the loading direction relativeto the module.
 10. A mounting system comprising: a chassis including aback wall, multiple guide rods connected to and extending from the backwall, multiple lifting elements disposed at or proximate to the backwall, and a support platform disposed below the guide rods; and a firstmodule configured to be mounted to the chassis in a stack with othermodules, the first module having a top side and a bottom side oppositethe top side, the first module defining a channel configured to receivea first guide rod of the guide rods therein, wherein the channel isspaced a designated height above the bottom side to enable the firstguide rod to enter the channel while the bottom side is disposed on thesupport platform, the first guide rod configured to guide movement ofthe first module relative to the support platform in a loading directiontowards the back wall, and wherein, as the first module is moved in theloading direction, the first module is configured to engage a firstlifting element of the lifting elements at an angled contact interfacebetween the first lifting element and the first module, and the angledcontact interface causes the first module to lift off the supportplatform with additional movement of the first module in the loadingdirection, wherein, in a fully loaded position relative to the chassis,the first module is supported by one or more of the back wall, the firstlifting element, or the first guide rod, and the bottom side of thefirst module is spaced apart from the support platform by a gap.
 11. Themounting system of claim 10, further comprising a second moduleconfigured to be mounted to the chassis above the first module such thatthe first module is between the second module and the support platform,wherein the second module is at least partially supported by the topside of the first module as the second module moves in the loadingdirection, and at least a second lifting element of the lifting elementsis configured to engage the second module at a second angled contactinterface between the second lifting element and the second module tolift the second module off the first module responsive to additionalmovement of the second module in the loading direction, and wherein, inthe fully loaded position, the second module is supported by one or moreof the back wall, the second lifting element, or the second guide rod,and the second module is spaced apart from the first module by a gap.12. The mounting system of claim 11, wherein the second module defines achannel configured to receive a second guide rod of the guide rodstherein to guide movement of the second module in the loading direction,and the channel is spaced a designated height above a bottom side of thesecond module to enable the second guide rod to enter the channel whilethe bottom side of the second module is disposed on the top side of thefirst module.
 13. The mounting system of claim 11, further comprising asupport member that is spaced apart from the back wall of the chassisand is mechanically coupled to both the first module and the secondmodule to restrict movement of the first and second modules relative toeach other.
 14. The mounting system of claim 10, wherein the firstmodule has a rear side that faces towards the back wall and a gasketmounted on the rear side, wherein the gasket is configured to becompressed between the rear side of the first module and the back wallwhen the first module is in the fully loaded position.
 15. The mountingsystem of claim 10, wherein the first module has a front side facingaway from the back wall, the first module including a shelf protrudingfrom the front side to define a front end of the first module, the shelfincludes a handle thereon, wherein the top side of the first moduleextends along the shelf.
 16. The mounting system of claim 10, whereinthe channel of the first module includes a rear opening at a rear sideof the first module, the rear opening being countersunk to provide aramp surface, wherein the ramp surface at the rear opening is configuredto engage the first lifting element and define a portion of the angledcontact interface.
 17. The mounting system of claim 10, wherein thefirst lifting element is mounted to the back wall at a location that isspaced apart from the first guide rod, and the first module defines areceptacle at a rear side of the first module, the receptacle spacedapart from the channel and configured to receive the first liftingelement therein to define a portion of the angled contact interface. 18.The mounting system of claim 10, wherein the first lifting element is awedge member that is mounted to the support platform, wherein the firstmodule includes a module wedge member mounted on the top side of thefirst module, the module wedge member on the first module representing asecond lifting element of the lifting elements configured to engage asecond module being mounted to the chassis above the first module at anangled contact interface to lift the second module off the first moduleresponsive to additional movement of the second module in the loadingdirection.
 19. The mounting system of claim 10, wherein the guide rodsare cantilevered and extend from the back wall to respective distal endsegments of the guide rods, wherein the mounting system also includesfasteners that are configured to releasably couple to the distal endsegments of the guide rods to exert clamp force on the first module andthe other modules for securing the first module and the other modules tothe chassis.
 20. A mounting system comprising: a module configured to bemounted to a chassis, the module including a housing having a top side,a bottom side opposite the top side, and a rear side extending betweenthe top side and the bottom side, the module defining a channelconfigured to receive a guide rod of the chassis therein, wherein thechannel is spaced a designated height above the bottom side to enablethe guide rod to enter the channel while the bottom side is disposed ona support platform, wherein movement of the module in a loadingdirection towards a back wall of the chassis while the bottom sideengages the support platform is guided by the guide rod within thechannel, wherein the module includes a ramp surface extending from therear side at a transverse orientation relative to the rear side, theramp surface configured to engage a contact surface of a lifting elementof the chassis as the module approaches the back wall to define anangled contact interface that, wherein the ramp surface of the module isconfigured to slide against the contact surface of the lifting elementat the angled contact interface as the module is moved in the loadingdirection to lift the module off the support platform, wherein thebottom side of the module is configured to be spaced apart from thesupport platform by a gap when the module is in a fully loaded positionrelative to the chassis.